Arrangement structure of non-contact charging device

Abstract

To provide an arrangement structure of a non-contact charging device that allows the non-contact charging device to be arranged while securing an installation space for a battery.SOLUTION: In an arrangement structure of a non-contact charging device 1 which can charge a battery 4 mounted on a vehicle in a non-contact manner, the non-contact charging device 1 comprises: a secondary coil 11 which is provided so as to face a primary coil of a power supply device; and a power conversion unit 12 which converts AC power transmitted from the primary coil to the secondary coil 11 into DC power capable of charging the battery 4. The vehicle is equipped with a vehicle drive device 5 including: a travel motor M driven by power from the battery 4; a housing H accommodating the travel motor M; and an oil pan HP which is provided at the bottom of the housing H and which stores oil for cooling the travel motor M. The oil pan HP includes an inclined surface 70 whose bottom is inclined with respect to a horizontal surface, and at least a portion of the power conversion unit 12 is provided so as to face the inclined surface 70.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to an arrangement structure of a non-contact charging device capable of charging a battery mounted on a vehicle without contact.

Background Art

[0002] Conventionally, technologies for non-contact charging of batteries mounted on vehicles have been studied. As such a technology, for example, there is one described in Patent Document 1 cited below.

[0003] Patent Document 1 describes a vehicle equipped with a battery capable of non-contact charging. This vehicle includes a power receiving unit that receives power non-contact from a power transmission unit of a power supply device, and an electric drive device that generates a driving force for vehicle propulsion using the power received by the power receiving unit. An oil pan is provided inside the power receiving coil of the power receiving unit.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] In the vehicle described in Patent Document 1, while power is being supplied from the power transmission unit to the power reception unit, the oil in the oil pan is heated by the electromagnetic field generated around the power reception coil. However, when the oil is heated during vehicle travel, even when the vehicle stops, the power reception coil will be heated until the temperature of the oil drops. Since the allowable current of the power reception coil decreases as the temperature increases, the power supply efficiency in the power supply unit decreases until the temperature of the oil drops, and the battery cannot be charged efficiently. Also, to improve the heat transfer efficiency from the power reception coil to the oil, it is necessary to arrange the power reception unit facing the oil pan, and space must be secured. As one way to secure such space, for example, reducing the size of the battery can be considered, but reducing the size of the battery will result in a decrease in the power capacity of the battery and a shortening of the vehicle's cruising range. Therefore, the technology described in Patent Document 1 has room for improvement.

[0006] Therefore, there is a need for an arrangement structure of a non-contact charging device that can arrange the non-contact charging device while securing the battery mounting space.

Means for Solving the Problems

[0007] The characteristic configuration of the arrangement structure of the non-contact charging device according to the present invention is an arrangement structure of a non-contact charging device capable of charging a battery mounted on a vehicle non-contact. The non-contact charging device includes a secondary coil provided to face the primary coil of the power supply device, and a power conversion unit that converts the AC power transmitted from the primary coil to the secondary coil into DC power capable of charging the battery. The vehicle includes a traveling motor driven by power from the battery, a housing that houses the traveling motor, and an oil pan provided at the bottom of the housing and storing oil for cooling the traveling motor. The oil pan includes an inclined surface whose bottom is inclined with respect to the horizontal plane, and at least a part of the power conversion unit is provided facing the inclined surface.

[0008] By inclining the bottom of the oil pan, it becomes easier to store oil. However, depending on the angle of the inclined surface of the oil pan with respect to the horizontal plane, it may be difficult to arrange vehicle equipment in the lower region of the inclined surface, resulting in dead space. However, according to this configuration, by arranging at least a part of the power conversion unit facing the inclined surface, the above-described dead space can be effectively utilized. Also, by providing the power conversion unit facing the inclined surface, the area where the battery can be provided can be further expanded, so that the battery capacity can be ensured. In addition, since the power conversion unit, the battery, and the vehicle drive device can be brought close to each other, the harness for electrically connecting them can be shortened. Therefore, power loss can be reduced and the weight of the harness can be reduced.

Brief Description of the Drawings

[0009]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Embodiments for Carrying Out the Invention

[0010] In the arrangement structure of the non-contact charging device according to the present invention, it is possible to arrange a non-contact charging device that can charge the battery in a non-contact manner while securing a mounting space for the battery mounted on the vehicle. Hereinafter, the arrangement structure of the non-contact charging device of the present embodiment (hereinafter referred to as "arrangement structure") will be described. However, the arrangement structure is not limited to the following embodiments, and various modifications are possible without departing from the gist thereof.

[0011] FIG. 1 shows a vehicle 2 equipped with a non-contact charging device 1. In FIG. 1, the front side in the traveling direction of the vehicle 2 is indicated by "F", and the rear side in the traveling direction of the vehicle 2 is indicated by "B". Further, FIG. 2 shows a diagram for explaining the arrangement structure of the present embodiment.

[0012] A battery 4 for storing electric power used for the running of the vehicle 2 is provided at the bottom 2A of the vehicle 2. The battery 4 is housed in a battery housing 10 so as to face the road surface 200 in order to prevent damage caused by small stones or the like that bounce up during the running of the vehicle 2. The battery housing 10 has a bottomed box shape using, for example, resin, and a housing space 10A is formed. The battery 4 is housed in this housing space 10A. The battery housing 10 is provided between a pair of front wheels FW and a pair of rear wheels RW at the bottom 2A facing the road surface 200 while the vehicle 2 is running.

[0013] The vehicle 2 is equipped with a vehicle drive device 5. The vehicle drive device 5 has a power supply module 5A and a running drive unit 5B. The power supply module 5A is provided at the upper part of the vehicle drive device 5, and the running drive unit 5B is provided at the lower part of the vehicle drive device 5. Therefore, in the present embodiment, the power supply module 5A and the running drive unit 5B are provided vertically (aligned in the vertical direction) along a direction orthogonal to both the traveling direction and the vehicle width direction of the vehicle 2.

[0014] The power supply module 5A includes an OBC (On Board Charger) board, a motor drive board, and a control board for controlling the OBC board and the motor drive board. The OBC board, the motor drive board, and the control board are each composed of a different board from each other.

[0015] For example, the OBC board and the motor drive board are provided side by side in the horizontal direction. The control board is arranged so as to overlap the OBC board and the motor drive board when viewed along the vertical direction (vertical view). The connection between the OBC board and the control board and the connection between the motor drive board and the control board are made via a board-to-board connector.

[0016] At least an AC / DC converter and a DC / DC converter are mounted on the OBC board. The AC / DC converter is supplied with AC power composed of an AC voltage from a commercial power supply, and converts the AC power into DC power including a DC voltage. The DC / DC converter is supplied with the DC power generated by the AC / DC converter, and boosts the voltage value of the DC voltage constituting the DC power supplied from the AC / DC converter to a DC voltage having a voltage value required for charging the battery 4. Further, the OBC board is provided with a capacitor for smoothing the DC voltage converted by the AC / DC converter and a capacitor for smoothing the DC voltage converted by the DC / DC converter.

[0017] At least a driving inverter for controlling a driving current for driving the traveling motor M is mounted on the motor drive board. Further, a control unit for controlling the AC / DC converter and the DC / DC converter is mounted on the control board.

[0018] The traveling drive unit 5B includes at least a traveling motor M that outputs power enabling the vehicle 2 to travel and a gear mechanism (not shown). The traveling motor M is driven by the power from the battery 4. The traveling motor M is driven by the above-described motor drive board. The gear mechanism decelerates and outputs the rotation of the traveling motor M. The rotational force of the traveling motor M is transmitted to a pair of front wheels FW via the gear mechanism. Thereby, the vehicle 2 can travel based on the rotational force output from the traveling motor M. However, the rotational force of the traveling motor M may be configured to be transmitted to a pair of rear wheels RW, or may be configured to be transmitted to a pair of front wheels FW and a pair of rear wheels RW.

[0019] FIG. 2 is a diagram showing the arrangement relationship between the non-contact charging device 1 and the vehicle drive device 5. As shown in FIG. 2, the traveling motor M and the gear mechanism are housed in the housing H. The traveling motor M and the gear mechanism are configured such that oil circulates by an oil pump P for the purpose of cooling. Below the housing H, an oil pan HP for storing oil for cooling the traveling motor M and the gear mechanism is provided. The oil pan HP includes an inclined surface 70 whose bottom is inclined with respect to the horizontal plane. An oil pump P is disposed in the region vertically below the oil pan HP. The region vertically below the oil pan HP is the region on the side of the inclined surface 70 close to the road surface 200. Therefore, the oil pump P is configured to suck the oil accumulated in the oil pan HP from the bottom side.

[0020] Returning to FIG. 1, the battery 4 is configured to be chargeable non-contact by the non-contact charging device 1. Non-contact charging means charging wirelessly, rather than charging via a harness, cable, etc. from the power supply device | apparatus 90. Of course, the battery 4 may be further chargeable via a harness, a cable, etc. in addition to non-contact charging.

[0021] As shown in FIG. 1, the non-contact charging device 1 includes a secondary coil 11 and a power conversion unit 12. When the battery 4 is charged, the vehicle 2 is parked so that the secondary coil 11 is provided to face the primary coil 91 of the power supply device 90. The primary coil 91 is buried in the ground with the power supply surface 91A exposed on the road surface 200. In the present embodiment, a cable 93 that electrically connects the power unit 92 of the power supply device 90 and the primary coil 91 is also buried in the ground. The primary coil 91 is supplied with AC power from the power unit 92 via the cable 93.

[0022] The power conversion unit 12 converts the AC power transmitted from the primary coil 91 to the secondary coil 11 into DC power capable of charging the battery 4. Power transmission from the primary coil 91 to the secondary coil 11 is performed, for example, by the magnetic resonance method. Of course, power transmission may be performed by the electromagnetic induction method. In any method, AC power transmitted from the primary coil 91 is generated in the secondary coil 11. The power conversion unit 12 converts this AC power into DC power. Note that the power conversion unit 12 may be configured to be able to convert the voltage value (step up or step down) when the voltage value of the DC power constituting the converted DC power is not suitable for charging the battery 4.

[0023] As described above, the power supply device 90 includes the primary coil 91 and the power unit 92. The power unit 92 has a power supply unit, a capacitor, an orthogonal conversion unit, and a control unit.

[0024] The power supply unit outputs DC power across a pair of electrodes. The voltage value of the DC voltage constituting the DC power output from the power supply unit is preferably suitable for the voltage value capable of charging the battery 4.

[0025] The capacitor is provided across a pair of electrodes. The capacitor smoothes the ripple voltage of the voltage and the ripple current of the current constituting the DC power output from the power supply unit.

[0026] The orthogonal conversion unit converts the DC power supplied across a pair of electrodes into AC power and supplies it to the primary coil 91. The orthogonal conversion unit has two legs provided in parallel with each other across a pair of electrodes. Each of the two legs has a high-side switching element and a high-side switching element connected in series with each other. These switching elements use n-type IGBTs (Insulated Gate Bipolar Transistors).

[0027] The collector terminals of the high-side switching elements of each of the two legs are electrically connected to one of a pair of electrodes. The emitter terminals of the low-side switching elements of each of the two legs are electrically connected to the other of the pair of electrodes. The emitter terminals of the high-side switching elements and the collector terminals of the low-side switching elements of each of the two legs are electrically connected. Further, the emitter terminal of the high-side switching element of one of the two legs is electrically connected to one terminal of the primary coil 91. The emitter terminal of the high-side switching element of the other of the two legs is electrically connected to the other terminal of the primary coil 91.

[0028] The orthogonal conversion unit is driven by the control unit to alternately switch between a first control state in which the high-side switching element of one leg and the low-side switching element of the other leg are closed and the low-side switching element of one leg and the high-side switching element of the other leg are open, and a second control state in which the low-side switching element of one leg and the high-side switching element of the other leg are closed and the high-side switching element of one leg and the low-side switching element of the other leg are open.

[0029] As shown in FIG. 2, at least a part of the power conversion unit 12 is provided below the inclined surface 70 facing the inclined surface 70. FIG. 3 shows a view of the vehicle drive device 5 as seen from below. As shown in FIG. 3, in a vertical direction view, the power conversion unit 12 may be configured such that not all of it overlaps with the inclined surface 70 and a part of it overlaps.

[0030] The power conversion unit 12 has two legs provided in parallel with each other across a pair of terminals of the battery 4. Each of the two legs has a high-side switching element and a low-side switching element connected in series with each other. In the present embodiment, n-type IGBTs are also used as these switching elements.

[0031] The collector terminals of the high-side switching elements of each of the two legs are electrically connected to one terminal of the battery 4. The emitter terminals of the low-side switching elements of each of the two legs are electrically connected to the other terminal of the battery 4. The emitter terminal of the high-side switching element of one of the two legs and the collector terminal of the low-side switching element of one of the two legs are electrically connected. Also, the emitter terminal of the high-side switching element of the other of the two legs and the collector terminal of the low-side switching element of the other of the two legs are electrically connected. Further, the emitter terminal of the high-side switching element of the other of the two legs and the collector terminal of the switching element of the other of the two legs are electrically connected.

[0032] Also, the emitter terminal of the high-side switching element of one of the two legs is electrically connected to one terminal of the secondary coil 11. The emitter terminal of the switching element of the other of the two legs is electrically connected to the other terminal of the secondary coil 11.

[0033] When AC power is transmitted from the primary coil 91 to the secondary coil 11, the power conversion unit 12 is driven by a control unit (not shown) to alternately switch between a third control state in which the high-side switching element of one leg and the low-side switching element of the other leg are closed and the low-side switching element of one leg and the high-side switching element of the other leg are open, and a fourth control state in which the low-side switching element of one leg and the high-side switching element of the other leg are closed and the high-side switching element of one leg and the low-side switching element of the other leg are open. As a result, it becomes possible to charge the battery 4 with the DC power converted by the power conversion unit 12.

[0034] Diodes are provided across the emitter terminals and collector terminals of the high-side switching element and the low-side switching element, respectively. The cathode terminal of the diode is electrically connected to the collector terminal of each of the high-side switching element and the low-side switching element, and the anode terminal is electrically connected to the emitter terminal of each of the high-side switching element and the low-side switching element.

[0035] Here, the power conversion unit 12 includes a heat generating portion whose heat generation amount in response to energization is equal to or greater than a predetermined value, and a non-heat generating portion whose heat generation amount is less than the predetermined value. The heat generation amount in response to energization is the heat generation amount when the power conversion unit 12 is driven. When the power conversion unit 12 is driven, the above-described high-side switching element and low-side switching element have a relatively large heat generation amount. On the other hand, when the power conversion unit 12 is driven, the above-described diode has a relatively small heat generation amount. For this reason, the heat generating portion corresponds to the high-side switching element and the low-side switching element, and the non-heat generating portion corresponds to the diode. Of course, when the power conversion unit 12 includes components other than these (for example, a capacitor), the component is also classified into one of the heat generating portion and the non-heat generating portion.

[0036] Here, as described above, the oil pan HP has an inclined surface 70 on the bottom surface. Oil that has cooled the traveling motor M and the gear mechanism accumulates in this oil pan HP, and this oil is sucked in by the oil pump P, passes through a heat exchanger such as an oil cooler (not shown) to lower the temperature of the oil, and is then used for cooling again. For this reason, the temperature of the oil pan HP is higher in the vertically lower region than in the vertically upper region. Therefore, in the present embodiment, the heat generating portion is provided to face the vertically upper region of the inclined surface 70. Thereby, the heat generating portion in the power conversion unit 12 can be separated from the oil stored in the oil pan HP. Therefore, it is possible to make it difficult for the switching element included in the power conversion unit 12 to be heated by the oil.

[0037] Furthermore, in the present embodiment, as shown in FIG. 2, the power conversion unit 12 is provided in a state of being separated from the oil pan HP. Thereby, an air layer can be provided between the power conversion unit 12 and the oil pan HP, so that heat transfer across the power conversion unit 12 and the oil pan HP can be suppressed. Therefore, it is possible to further suppress the power conversion unit 12 from being heated by the oil due to the switching elements it has.

[0038] Also, the support member that supports the non-contact charging device 1 may be integrated with the oil pan HP. Such integration may be achieved by fastening and fixing with bolts or by integrating the housing H. In these cases, since the non-contact charging device 1 can be supported via the oil pan HP, there is no need to separately provide a support member. Therefore, weight reduction can be achieved.

[0039] 〔Other Embodiments〕 Next, other embodiments of the arrangement structure of the non-contact charging device 1 will be described.

[0040] In the above embodiment, the power conversion unit 12 includes a heat generating portion with a heat generation amount of a predetermined value or more in response to energization and a non-heat generating portion with a heat generation amount less than the predetermined value, and the heat generating portion has been described as being provided to face the vertically upper region of the inclined surface 70 of the oil pan HP. However, the power conversion unit 12 can also be configured without including the non-heat generating portion. Also, the heat generating portion can be provided without facing the vertically upper region of the inclined surface 70 of the oil pan HP.

[0041] In the above embodiment, the vehicle drive device 5 has been described as having an oil pump P disposed in the vertically lower region of the oil pan HP. However, the vehicle drive device 5 can also be configured without having the oil pump P, and the oil pump P can also be disposed in the vertically upper region of the oil pan HP.

[0042] In the above-described embodiment, the heat generating part has been described as being provided to face the region vertically above on the inclined surface 70. However, the heat generating part can also be provided to face the region vertically below on the inclined surface 70.

[0043] In the above-described embodiment, the power conversion unit 12 has been described as being provided in a state separated from the oil pan HP. However, the power conversion unit 12 can also be provided in a state in contact with the oil pan HP.

[0044] In the above-described embodiment, the support member that supports the non-contact charging device 1 has been described as being integrated with the oil pan HP. However, the support member can also be configured separately from the oil pan HP.

[0045] In the above-described embodiment, at least a part of the power conversion unit 12 has been described as being provided to face the inclined surface 70. However, as shown in FIG. 4, all of the power conversion unit 12 may be provided to face the inclined surface 70. Also, in FIG. 2, the part on the rear side B in the traveling direction of the vehicle 2 in the power conversion unit 12 is shown as being provided in a state where it does not face the inclined surface 70. However, as shown in FIG. 5, the part on the left side L in the traveling direction of the vehicle 2 in the power conversion unit 12 may be provided in a state where it does not face the inclined surface 70, or as shown in FIG. 6, the part on the right side R in the traveling direction of the vehicle 2 in the power conversion unit 12 may be provided in a state where it does not face the inclined surface 70.

[0046] 〔Outline of the above embodiment〕 Hereinafter, an outline of the arrangement structure of the non-contact charging device 1 described above will be described.

[0047] (1) The arrangement structure of the non-contact charging device 1 is an arrangement structure of a non-contact charging device 1 that can charge the battery 4 mounted on the vehicle 2 in a non-contact manner. The non-contact charging device 1 includes a secondary coil 11 provided to face the primary coil 91 of the power supply device 90, and a power conversion unit 12 that converts the AC power transmitted from the primary coil 91 to the secondary coil 11 into DC power capable of charging the battery 4. The vehicle 2 includes a traveling motor M driven by the power from the battery 4, a housing H that houses the traveling motor M, and an oil pan HP provided at the bottom of the housing H and storing oil for cooling the traveling motor M. The oil pan HP includes an inclined surface 70 whose bottom is inclined with respect to the horizontal plane, and at least a part of the power conversion unit 12 is provided to face the inclined surface 70.

[0048] By inclining the bottom of the oil pan HP, it becomes easier to store oil. However, in the lower region of the inclined surface 70 of the oil pan HP, depending on the angle of the inclined surface 70 with respect to the horizontal plane, it may be difficult to arrange vehicle equipment and it may become a dead space. However, according to this configuration, by arranging at least a part of the power conversion unit 12 to face the inclined surface 70, the above-mentioned dead space can be effectively utilized. In addition, by providing the power conversion unit 12 to face the inclined surface 70, the area where the battery 4 can be provided can be further expanded, so that the battery capacity can be ensured. In addition, since the power conversion unit 12, the battery 4, and the vehicle drive device 5 can be brought close to each other, the harness for electrically connecting them can be shortened. Therefore, power loss can be reduced and the weight of the harness can be reduced.

[0049] (2) In the arrangement structure of the non-contact charging device 1 described in (1), the power conversion unit 12 includes a heat generating part whose heat generation amount in response to energization is equal to or more than a predetermined value, and a non-heat generating part whose heat generation amount is less than the predetermined value. The vehicle drive device 5 has an oil pump P arranged in the region vertically below the oil pan HP. It is preferable that the heat generating part is provided to face the region vertically above on the inclined surface 70.

[0050] In the oil pan HP having the inclined surface 70, oil after cooling the traveling motor M accumulates in the vertically lower region of the oil pan HP, and the temperature of the vertically lower region is higher than that of the vertically upper region. Therefore, according to this configuration, by providing the heat generating part in the inclined surface 70 facing the vertically upper region where oil does not accumulate (or accumulates less), it is possible to prevent the heat generating part from being further warmed by the oil. Accordingly, it is possible to prevent deterioration of the heat generating part and occurrence of thermal runaway.

[0051] (3) In the arrangement structure of the non-contact charging device 1 according to (1) or (2), it is preferable that the power conversion unit 12 is provided in a state of being separated from the oil pan HP.

[0052] According to this configuration, since an air layer can be provided between the power conversion unit 12 and the oil pan HP, heat transfer from one of the power conversion unit 12 and the oil pan HP to the other can be suppressed. Accordingly, it is possible to prevent deterioration of the power conversion unit 12 and occurrence of thermal runaway.

[0053] (4) In the arrangement structure of the non-contact charging device 1 according to any one of (1) to (3), it is preferable that the support member that supports the non-contact charging device 1 is integrated with the oil pan HP.

[0054] According to this configuration, the non-contact charging device 1 can be supported by the vehicle drive device 5. Accordingly, it becomes easy to provide the power conversion unit 12 facing the inclined surface 70 of the oil pan HP. [Industrial Applicability]

[0055] The technology according to the present disclosure can be used for an arrangement structure of a non-contact charging device capable of non-contact charging of a battery mounted on a vehicle. [Description of Signs]

[0056] 1: Non-contact charging device, 2: Vehicle, 4: Battery, 5: Vehicle drive device, 11: Secondary coil, 12: Power conversion unit, 70: Inclined plane, 91: Primary coil, H: Housing, HP: Oil pan, M: Traction motor, P: Oil pump

Claims

1. An arrangement structure of a non-contact charging device capable of charging a battery mounted on a vehicle without contact, The non-contact charging device includes a secondary coil provided to face a primary coil of a power supply device, and a power conversion unit that converts AC power transmitted from the primary coil to the secondary coil into DC power capable of charging the battery. The vehicle includes a driving motor driven by power from the battery, a housing that houses the driving motor, and an oil pan provided at the bottom of the housing and storing oil for cooling the driving motor, and includes a vehicle driving device. The oil pan includes an inclined surface whose bottom is inclined with respect to a horizontal plane. An arrangement structure of a non-contact charging device in which at least a part of the power conversion unit is provided to face the inclined surface.

2. The power conversion unit includes a heat generating part whose heat generation amount in response to energization is equal to or more than a predetermined value, and a non-heat generating part whose heat generation amount is less than the predetermined value. The vehicle driving device has an oil pump disposed in a region vertically below the oil pan. The heat generating part is an arrangement structure of the non-contact charging device according to claim 1, provided to face a region vertically above on the inclined surface.

3. The arrangement structure of the non-contact charging device according to claim 1 or 2, wherein the power conversion unit is provided in a state of being separated from the oil pan.

4. The arrangement structure of the non-contact charging device according to claim 1 or 2, wherein a support member that supports the non-contact charging device is integrated with the oil pan.

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