Electrical system for electric or hybrid vehicles, comprising a voltage converter, an inverter, and a control board on a single substrate

Abstract

The present invention relates to an electrical system (2) comprising: a housing (3) containing an electrical substrate (6); an inverter (8) housed in the housing (3) and configured to receive a direct current (DC) voltage from a battery and supply an alternating current (AC) voltage to an electrical machine; a control module (10) housed in the housing (3) and configured to control the power supply to the electrical machine by the inverter (8); the system (2) being characterized in that it comprises a DC-DC voltage converter (12) housed in the housing (3), the DC-DC voltage converter (12) being configured to step down a DC voltage from the battery to power electrical equipment, as well as the control module (10); the inverter (8), the control module (10), and the DC-DC voltage converter (12) being mounted on the electrical substrate (6). Abstract figure: Figure 3

Description

Title of the invention: Electrical system for an electric or hybrid vehicle, comprising a voltage converter, an inverter and a control card on the same substrate Technical field

[0001] The present invention relates to the technical field of electric or hybrid vehicles.

[0002] More particularly, the present invention relates to the technical field of wheel motors equipping an electric or hybrid vehicle and electrical systems for supplying electrical energy to such wheel motors. STATE OF THE ART

[0003] Known from the state of the art is an electric or hybrid vehicle comprising an electrical assembly formed by a rotating electrical machine supplied with electrical energy via a battery and an electrical system making it possible to adapt the electrical voltage delivered by the battery for the use of said electric machine. The battery of the electrical assembly can also supply electrical energy to at least one other electrical equipment of the vehicle, with a voltage different from the voltage necessary for the operation of the rotating electrical machine.Thus, there is known from the state of the art an electrical assembly comprising in particular an inverter configured to transform a direct voltage of the battery into alternating voltage to power the electrical machine, and comprising a direct-direct voltage converter configured to lower the direct voltage of the battery and power said equipment, for example to lower the voltage from 48V to 12V.

[0004] It is also known from the state of the art an electric or hybrid vehicle in which the electrical assembly is located at a wheel of said vehicle, housed in a casing around which the wheel is arranged. This configuration is commonly referred to as a "wheel motor" by those skilled in the art and has the advantage of significantly reducing the number of mechanical components between the rotating electrical machine and the wheel driven by said rotating electrical machine. However, such an electrical assembly must naturally have a minimal footprint constrained by its location in the wheel of said vehicle. Thus, this so-called "wheel motor" architecture is not compatible with standard safety criteria, requiring electrical isolation of the electrical circuit of the inverter from the electrical circuit of the DC-DC voltage converter.In fact, in this configuration, the electrical connection connects the battery to the inverter and the voltage converter respectively. DC-DC each include distinct and / or identical electrical components, such as capacitive modules configured to smooth the voltage delivered by the battery, thereby giving the assembly a significant footprint.

[0005] Nevertheless, for certain applications, falling within the scope of “soft mobility”, it is not necessary to electrically isolate the electrical circuit of the inverter from the electrical circuit of the direct-direct voltage converter, because the powers implemented are lower.

[0006] The invention therefore aims to resolve all or part of the drawbacks of the state of the art, in particular by proposing an electrical assembly, comprising at least one inverter and a direct voltage converter, the compactness of which is adapted to a “motor-wheel” vehicle architecture. PRESENTATION OF THE INVENTION

[0007] More specifically, the invention relates to an electrical system, comprising: 1. a housing housing a flat electrical substrate; 2. an inverter housed in the housing and configured to receive a voltage direct current from a battery and supply alternating current to at least one rotating electrical machine; 3. at least one control module housed in the housing and configured to control the power supply of the rotating electrical machine by the inverter;

[0008] The system is notable in that it comprises a DC-DC voltage converter housed in the housing, the DC-DC voltage converter being configured to step down a DC electrical voltage from the battery to power at least one piece of electrical equipment as well as the control module; the inverter, the control module and the DC-DC voltage converter being mounted on the electrical substrate.

[0009] Thanks to such a combination of characteristics, the electronic components forming the inverter and the electrical components forming the DC-DC voltage converter are mounted on the same electrical substrate, reducing the number of mechatronic parts required and simplifying assembly. Also, the overall size of the electrical system is significantly reduced.

[0010] Advantageously, the inverter comprises a capacitive module electrically connected to the DC-DC voltage converter via the electrical substrate. In addition, the electrical system comprises a terminal block capable of being connected to the battery, allowing the capacitive module to deliver a smoothed DC voltage to the active components of the DC-DC voltage converter and to the active components of the inverter. In such a configuration, the inverter and the voltage converter DC-DC converters are connected in parallel. By pooling the capacitive module, which is therefore common to the inverter and the DC-DC voltage converter, the assembly of the electrical system is further simplified.

[0011] Advantageously, the inverter, the DC-DC voltage converter and the control module are substantially coplanar and mounted on the same first face of the flat electrical substrate. In such a configuration, the overall size of the system is further reduced.

[0012] Advantageously, the casing delimits an annular cylindrical parallelepiped housing, the flat electrical substrate having an annular section. In such a configuration, the casing and the substrate can be crossed by an axle or a transmission shaft.

[0013] According to another aspect of the invention, it relates to an on-board electrical assembly, comprising: 1. an electrical system as described above; 2. a battery configured to provide DC voltage to the inverter and DC-DC voltage converter of the electrical system; 3. a rotating electrical machine receiving an alternating electrical voltage from the inverter of the electrical system; 4. at least one electrical device receiving a direct electrical voltage from the direct-direct voltage converter.

[0014] Advantageously, the electrical machine comprises a stator secured to an axle and a rotor capable of rotating relative to the stator, the electrical system being secured to the stator.

[0015] Advantageously, the casing of the electrical system delimits an annular cylindrical parallelepiped housing, the planar electrical substrate having an annular section, the axle delimiting an inner diameter of the casing and the stator delimiting an outer diameter of the casing. In such a configuration, the electrical assembly can rotate a mechanical element secured to an outer diameter of the rotor of the electrical machine.

[0016] According to another aspect of the invention, it relates to an electric vehicle comprising an electrical assembly as described above.

[0017] Advantageously, the electrical assembly is located at a wheel of said vehicle. Preferably, the wheel is integral with an outside diameter of the rotor of the electrical machine of the assembly. PRESENTATION OF FIGURES

[0018] The invention will be better understood on reading the following description, given solely by way of example, and referring to the appended drawings given as of non-limiting examples, in which identical references are given to similar objects and on which:

[0019] [Fig.l] is a schematic representation in isometric perspective of an electrical assembly according to a first aspect of the invention;

[0020] [Fig.2] is a schematic representation in front view of the electrical assembly of [Fig.l] in a position removed from a cover of the assembly;

[0021] [Fig. 3] is a schematic representation in front view of an electrical system according to another aspect of the invention;

[0022] [Fig.4] is a schematic representation in rear view of the electrical system of [Fig.3];

[0023] It should be noted that the figures set out the invention in detail to enable the invention to be implemented; although not limiting, said figures serve in particular to better define the invention where appropriate. DETAILED DESCRIPTION OF THE INVENTION

[0024] The invention relates to an on-board electrical assembly 1, as illustrated in [Fig. 1] and in [Fig. 2]. The electrical assembly 1 is configured to rotate a mechanical element to which it is secured, for example a wheel of an electric or hybrid vehicle (not illustrated). Preferably, the electrical assembly 1 is then located at a wheel of said vehicle, inside the wheel. This configuration is commonly referred to as a “wheel motor” by those skilled in the art.

[0025] To rotate the wheel or the mechanical element to which it is attached, the electrical assembly 1 comprises a rotating electrical machine 5. Furthermore, the electrical assembly 1 comprises at least one other piece of electrical equipment, for example a headlight of the vehicle. It should be noted that the electrical equipment may be located at a distance from the wheel of said vehicle and from the rest of the electrical assembly 1. More particularly, the rotating electrical machine comprises a stator 7 attached to an axle 11 and a rotor 9 movable in rotation relative to the stator 7 and relative to the axle 11, for example by means of a ball bearing. Here, the wheel is attached to an outside diameter of the rotor 9. Advantageously, at least one cover is interposed between the rotor 9 and said wheel.

[0026] To supply energy to the electrical machine 5 as well as to the electrical equipment, the electrical assembly comprises at least one battery (not shown). The battery is configured to deliver to its terminals a direct voltage, for example a direct voltage of 48V. Since this voltage cannot be used as is by the electrical machine 5 and the electrical equipment, the battery 3 is connected to an electrical system 2 supplying an alternating electrical voltage to the rotating electrical machine 5 and a lower direct electrical voltage to the electrical equipment.

[0027] The remainder of the description focuses on describing the electrical system 2. The electrical system 2 comprises a casing 3 housing a flat electrical substrate 6. In [Fig. 1], the casing 3 is for example made in two assemblable parts. The body of the stator 7 forming the casing 3 here delimits a generally annular cylindrical parallelepiped housing. The substrate 6 is advantageously fixed to a heat sink, also housed in the casing 3 and integral with the axle 11.

[0028] The electrical substrate 6 is in particular an electrical substrate called FR4, here having an annular section, and making it possible to electrically connect electronic components mounted on its faces, by the internal layers constituting it. Thanks to its annular section, the substrate can be crossed by the axle 11. To provide the electrical machine 5 with an alternating voltage from the direct voltage received from the battery, the electrical system 2 comprises electronic components mounted on the substrate 6 to form an inverter 8 housed in the casing 3. To control the power supply of the electrical machine 5 by the inverter 8, the electrical system 2 comprises at least one control module 10, housed in the casing 3 and mounted on the substrate 6. The control module 10 may in particular comprise a gate control, a microcontroller and / or an on-board computer.

[0029] To provide the electrical equipment with a DC voltage lower than the voltage received from the battery, the electrical system 2 comprises electrical components mounted on the substrate 6 to form a DC-DC voltage converter 12, commonly referred to as a “Buck”. Furthermore, the DC-DC voltage converter 12 is also configured to power the control module 10. The DC-DC voltage converter 12 is for example configured to lower the voltage received from the battery initially at 48V to a voltage of 12V.

[0030] Thanks to such a combination of characteristics, the electronic components forming the inverter 8 and the electrical components forming the DC-DC voltage converter 12 are mounted on the same substrate 6, reducing the number of mechatronic parts required and simplifying assembly. Also, the overall size of the electrical system is significantly reduced. As a result, electrical tracks having different voltages extend over the same substrate.

[0031] To smooth and filter the voltage delivered by the battery to the inverter 8, the inverter 8 advantageously comprises a capacitive module. The capacitive module comprises at least one connecting capacitor 14. The capacitive module is electrically connected to the DC-DC voltage converter via the substrate 6. Preferably, the electrical system 2 comprises a terminal block 16 capable of being connected to the battery and allowing the capacitive module to deliver a smoothed DC voltage to the active components of the DC-DC voltage converter 12 and to the active components of the inverter 8. In such a configuration, the inverter 8 and the converter DC-DC voltage 12 are connected in parallel. By pooling the capacitive module in this way, the assembly of the electrical system is further simplified, reducing the number of capacitors required to smooth the voltage. In the illustrated embodiment, the terminal block 16 passes through the substrate 6 due to its annular section. This configuration may vary, in particular depending on the location of the battery of the electrical assembly 1, on one side or the other side of the substrate 6.

[0032] In the embodiment illustrated, in particular in [Fig. 3], the components of the inverter 8, of the DC-DC voltage converter 12 and of the control module 10 are substantially coplanar, and mounted on the same first face of the substrate 6. The plane in which the components extend is preferably a plane parallel to a plane in which the substrate 6 extends. In such a configuration, the overall size of the system, and in particular the size along the axis of rotation of the rotating electrical machine 5, is reduced.

[0033] As illustrated in [Fig.4], the electrical system advantageously comprises a phase interface 18. The interface 18 is mounted on the first face of the substrate 6 and through the substrate 6, to a second face of the substrate 6. The phase interface 18 is configured to electrically connect the inverter 8 to the electrical machine 5. In the embodiment described, the connecting capacitors 14 are mounted on the second face of the substrate 6 and pass through said substrate 6 from the second face to the first face. Preferably, the interface 18 and the connecting capacitors 14 are coplanar. In fact, the overall size of the system, and in particular the size along the axis of rotation of the rotating electrical machine 5, is reduced.

[0034] It will also be noted that the invention is not limited to the embodiments described above. It will indeed appear to those skilled in the art that various modifications can be made to the embodiment described above, in light of the teaching which has just been disclosed to them.

[0035] In the detailed presentation of the invention which is made above, the terms used must not be interpreted as limiting the invention to the embodiment set out in the present description, but must be interpreted to include all equivalents whose prediction is within the reach of a person skilled in the art by applying his general knowledge to the implementation of the teaching which has just been disclosed to him.

Claims

Claims

1. Electrical system (2), comprising:

1. a housing (3) housing a flat electrical substrate (6); 2. an inverter (8) housed in the housing (3) and configured to receive a direct electrical voltage from a battery and supply an alternating electrical voltage to at least one rotating electrical machine (5); 3.at least one control module (10) housed in the casing (3) and configured to control the power supply of the rotating electrical machine (5) by the inverter (8); the electrical system (2) being characterized in that it comprises a DC-DC voltage converter (12) housed in the casing (3), the DC-DC voltage converter (12) being configured to lower a DC electrical voltage of the battery to power at least one piece of electrical equipment as well as the control module (10); the inverter (8), the control module (10) and the DC-DC voltage converter (12) being mounted on the electrical substrate (6).

2. Electrical system (2) according to claim 1, wherein the inverter (8) comprises a capacitive module electrically connected to the DC-DC voltage converter (12) via the electrical substrate (6).

3. Electrical system (2) according to any one of the preceding claims, in which the inverter (8), the DC-DC voltage converter (12) and the control module (10) are substantially coplanar and mounted on the same first face of the flat electrical substrate (6).

4. Electrical system (2) according to any one of the preceding claims, in which the casing (3) delimits an annular cylindrical parallelepiped housing, the flat electrical substrate (6) having an annular section.

5. An on-board electrical assembly (1), comprising:

1. an electrical system (2) according to any one of claims 1 to 4; 2. a battery configured to supply a direct voltage to the inverter (8) and to the direct-direct voltage converter (12) of the electrical system (2); an electrical machine (5) rotating receiving an alternating electrical voltage from the inverter (8) of the electrical system; 3. at least one electrical equipment receiving a direct electrical voltage from the direct-direct voltage converter (12).

6. On-board electrical assembly (1) according to claim 5, in which the electrical machine (5) comprises a stator (7) secured to an axle (11) and a rotor (9) movable in rotation relative to the stator (7), the electrical system (1) being secured to the stator (7).

7. On-board electrical assembly (1) according to claim 6, in which the casing (3) of the electrical system (1) delimits an annular cylindrical parallelepiped housing, the planar electrical substrate (6) having an annular section, the axle (11) delimiting an internal diameter of the casing (3) and the stator (7) delimiting an external diameter of the casing (3).

8. An electric vehicle comprising an electrical assembly (1) according to any one of claims 5 to 7.

9. An electric vehicle according to claim 8, wherein the electrical assembly (1) is located at a wheel of said vehicle.

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