Installed power conversion equipment

Abstract

To improve EMC performance while suppressing increases in costs in a stationary power conversion device. [Solution] The installed power conversion device (10) includes a main body component (80) that constitutes a housing (24), two intermediate support members (71, 72) fixed to the inner surface of the main body component (80) so as to protrude on the same side, and a tip support member (73) fixed to the tips of the two intermediate support members (71, 72). An intermediate side electronic board (17, 18) is supported on at least one of the two intermediate support members (71, 72). A tip side electronic board (19) is supported on the tip support member (73). Each of the intermediate support members (71, 72), the tip support member (73), and the main body component (80) form a cylindrical section (70) made of metal.

Description

[Technical Field]

[0001] The present disclosure relates to a stationary power conversion device. [Background technology]

[0002] Conventionally, a stationary power conversion device called a charging stand, which is installed outdoors, has been used to charge the onboard batteries of electric vehicles such as electric cars, hybrid cars, and plug-in hybrid cars. The stationary power conversion device includes a box-shaped housing and electronic circuit components for power conversion that are provided inside the housing.

[0003] In Patent Document 1, electronic circuit components are arranged inside a box-shaped housing, and a terminal block is provided inside a terminal block cover provided on the outside of the lower side of the housing. AC or DC power input to the terminal block is converted into DC power required by an on-board battery, and the converted DC power is output from a charging connector provided at the end of a charging cable extended from the upper side of the housing. The charging connector is connected to a charging port of an electric vehicle. This allows the required DC power to be charged from the stationary power conversion device to the on-board battery. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2020-36456 Summary of the Invention [Problem to be solved by the invention]

[0005] In a stationary power conversion device, reducing the effects of radiated noise on signal lines is important in terms of improving EMC performance, which is the ability to suppress noise generation and reduce noise effects. However, in a power conversion device, signal lines and power lines tend to be placed close to each other in a small space, making it difficult to reduce the effects of radiated noise. While it is possible to suppress noise by inserting the power line harness into a ferrite core, this is undesirable due to the increased cost. It is therefore desirable to improve EMC performance while suppressing the increase in cost. [Means for solving the problem]

[0006] The installed power conversion device according to the present disclosure comprises a main body component constituting a housing, two intermediate support members fixed to the inner surface of the main body component so as to protrude to the same side, and a tip support member fixed to the tip of the two intermediate support members, wherein at least one of the two intermediate support members supports an intermediate electronic board, and the tip support member supports a tip electronic board, and the respective intermediate support members, tip support members, and main body component form a cylindrical portion made of metal. [Effects of the Invention]

[0007] According to the installed power conversion device of the present disclosure, even though signal lines and power lines are likely to be arranged close to each other in a narrow space, it is possible to improve EMC performance while suppressing cost increases without using expensive power lines that use ferrite cores. [Brief explanation of the drawings]

[0008] [Figure 1A] 1 is a block diagram of a power supply system including a stationary power conversion device according to an embodiment. [Figure 1B] FIG. 2 is a diagram showing a current flow in a configuration diagram of a stationary power conversion device according to an embodiment. [Figure 2] 1 is a perspective view of an installed power conversion device according to an embodiment, seen from the front side; [Figure 3]FIG. 3 is a perspective view of the installed power conversion device of FIG. 2 as seen from the rear side. [Figure 4] FIG. 3 is a perspective view of the cross section AA of FIG. 2. [Figure 5] FIG. 3 is a perspective view of the cross section BB of FIG. 2. [Figure 6] 3 is a front view of the installed power conversion device of FIG. 2, with the front side panel and terminal box cover omitted. FIG. [Figure 7] FIG. 3 is an exploded perspective view of the installed power conversion device of FIG. 2. [Figure 8] 1 is a perspective view, seen from below, of a state in which a terminal box is connected to the lower end of a first housing in an embodiment. [Figure 9] 3 is a perspective view of the fixed structure of the second housing and the terminal box taken out from the installed power converter of FIG. 2, with some parts omitted, as viewed from the front side. FIG. [Figure 10] FIG. 10 is a perspective view of the terminal box shown in FIG. 9, seen from the front side with the terminal box cover omitted. [Figure 11] FIG. 10 is a perspective view showing the terminal box removed from FIG. 9. [Figure 12] FIG. 2 is a front perspective view of the terminal box in the embodiment, showing a state in which a power transmission cable is connected to the terminal box. [Figure 13] FIG. 13 is a perspective view of the terminal box shown in FIG. 12 as seen from the rear side. [Figure 14] 13 is a perspective view of the terminal box shown in FIG. 12, seen from the front, with the terminal box cover, the power transmission cable, the signal line, and the ground wire omitted. FIG. [Figure 15] 3 is a perspective view showing the lower part of the installed power conversion device shown in FIG. 2, with the front side panel and terminal box cover of the second housing omitted. FIG. [Figure 16] FIG. 16 is a perspective view of FIG. 15 as seen obliquely from below. [Figure 17] FIG. 2 is a perspective view of the terminal box cover as seen from the rear side. [Figure 18] FIG. 10 is a perspective view of the fixing structure of the second housing and the terminal box as seen from the rear side. [Figure 19]19 is a perspective view showing the fixing structure shown in FIG. 18 with the rear end side panel removed. FIG. [Figure 20] 20 is a perspective view showing the state in which the house-side power transmission cable is inserted from the rear side of the second housing in the fixing structure shown in FIG. 19. FIG. [Figure 21] 20, and (b) is a view corresponding to (a) of a stationary power conversion device of a comparative example. [Figure 22] 16 is a cross-sectional view taken along CC in FIG. 15. [Figure 23] 3 is a perspective view showing the lower part of the installed power conversion device shown in FIG. 2, with the front and left side panels of the second housing and the terminal box cover omitted. FIG. [Figure 24] 24 is a perspective view showing a state immediately before the vehicle-side power transmission cable and the clamp assembly are assembled to the second housing main body to achieve the state shown in FIG. 23. FIG. [Figure 25] FIG. 25 is a perspective view showing the clamp assembly removed from FIG. 24. [Figure 26] FIG. 26 is an exploded perspective view of the clamp assembly shown in FIG. 25. [Figure 27] FIG. 3 is a perspective view showing the installed power conversion device shown in FIG. 2 with the front and left and right side panels omitted. [Figure 28] FIG. 28 is an exploded perspective view of FIG. 27. [Figure 29] 28 is a cross-sectional view taken along the line DD in FIG. 27. [Figure 30] 3 is a perspective view of the installed power conversion device shown in FIG. 2, with some components omitted, showing a state in which a signal line passes through an inner space surrounded by a second support member, a third support member, and a main body panel. [Figure 31] 31 is a view of the vertical intermediate portion of the installed power conversion device shown in FIG. 30 as seen from the front side. FIG. [Figure 32] FIG. 29 is a perspective view of the heat sink block taken out from FIG. 28 and seen from the front side. [Figure 33] FIG. 33 is a perspective view of the heat sink block shown in FIG. 32 as seen from the rear side. [Figure 34]FIG. 33 is an exploded perspective view of the heat sink block shown in FIG. 32. [Figure 35] FIG. 29 is an enlarged perspective view of a portion E in FIG. 28. [Figure 36] FIG. 29 is an enlarged perspective view showing the second assembly, the third assembly, and the fourth assembly taken out from FIG. 28. [Figure 37] 37 is a perspective view showing a state immediately before substrates are fixed to both side surfaces of a second support member that constitutes one of the two second assemblies shown in FIG. 36. FIG. [Figure 38] FIG. 37 is a perspective view showing an inner surface of the other of the two second assemblies shown in FIG. 36 . [Figure 39] FIG. 2 is a perspective view showing a state in which a first assembly, a second housing, and a terminal box are fixed to a main body panel that constitutes a stationary power conversion device in an embodiment. [Figure 40] FIG. 10 is a perspective view showing a first step in a method for fixing a heat sink block to a main body panel. [Figure 41] FIG. 41 is an enlarged perspective view of part F in FIG. 40. [Figure 42] 42 is a view corresponding to FIG. 41 and illustrating a second stage of the fixing method for fixing the heat sink block to the main body panel. [Figure 43] 10 is a schematic diagram showing the connection state and arrangement of a plurality of electronic boards supported by a heat sink block and second, third, and fourth support members, laid out along a plane. FIG. [Figure 44] 1 is a circuit diagram of a power conversion circuit in a stationary power conversion device according to an embodiment. [Figure 45] 30 is a schematic diagram corresponding to FIG. 29, showing the arrangement of parts arranged inside and outside a cylindrical portion formed by a main body panel, a second support member, and a third support member. FIG. [Figure 46] 45(a) is a schematic diagram corresponding to FIG. 45 showing adjacent electronic boards connected by a harness, and FIG. 45(b) is a schematic diagram corresponding to FIG. 45 showing adjacent electronic boards connected by a board-to-board connector. [Figure 47]46A and 46B are views corresponding to FIG. 45 and showing three other examples of the arrangement of parts to be arranged inside and outside the cylindrical portion. [Figure 48] FIG. 10 is a block diagram showing a power supply system including a stationary power conversion device according to another embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] Below, a stationary power conversion device according to an embodiment of the present disclosure will be described in detail with reference to the drawings. The drawings referred to in the description of the embodiments are schematic, and therefore the dimensional ratios of each component should be determined with reference to the following description. In the following description, specific shapes, materials, numerical values, quantities, etc. are examples for facilitating understanding of the present disclosure. It is anticipated from the beginning that the components of the multiple embodiments described below will be selectively combined. Below, similar elements will be denoted by the same reference numerals in all drawings. Below, a stationary power conversion device will be described that is used to convert power supplied from a house, such as a detached house, and then transmit the converted power to a vehicle to charge the vehicle's battery. Meanwhile, the stationary power conversion device according to the present disclosure may also be configured to convert power supplied from facilities such as car dealerships, supermarkets, gas stations, hotels, and hospitals, and then transmit the converted power to a vehicle.

[0010] FIG. 1A is a block diagram of a power supply system 300 including a stationary power conversion device 10 according to an embodiment. Hereinafter, the stationary power conversion device 10 will be referred to as the power conversion device 10. The power supply system 300 supplies DC power to the power conversion device 10 from, for example, a house such as a detached house via a house-side power transmission cable 12. The power conversion device 10 is installed outdoors. The power conversion device 10 converts the DC power supplied from the house 1 into DC power required by an on-board battery 3 of an electric vehicle 2, and outputs the DC power to a vehicle-side power transmission cable 14. A vehicle-side connector 15 of the vehicle-side power transmission cable 14 is connected to a charging port (not shown) of the electric vehicle 2. In this state, DC power is supplied to the on-board battery 3 of the electric vehicle 2, and the on-board battery 3 is charged.

[0011] When the electric vehicle 2 is parked at night, for example, power can be supplied from the on-board battery 3 of the electric vehicle 2 to the power conversion device 10, and the power can be converted by the power conversion device 10 and a power conversion circuit 4 for a storage battery in the house 1. The converted DC power can then be supplied to a stationary storage battery 5, which charges the storage battery 5.

[0012] More specifically, a solar cell module 6 is installed on the roof of a house 1 shown in FIG. 1A. The solar cell module 6 is connected to a power station 7 inside the house 1. The power station 7 is also called a power conditioner, and includes a power conversion circuit 7a for the solar cell and an inverter 7b connected to the power conversion circuit 7a. The power station 7 converts DC power generated by the solar cell module 6 into the required DC power using the power conversion circuit 7a, and then converts this into AC power using the inverter 7b. The converted AC power is output to an AC power main line (primary main line) via a distribution board 8. The AC power converted by the power station 7 is also supplied to various electrical devices or facilities (not shown) inside the house.

[0013] The house-side power transmission cable 12 of the power conversion device 10 is connected between the power conversion circuit 7a and the inverter 7b. The power conversion circuit 7a and the inverter 7b are also connected to a stationary storage battery 5 via a power conversion circuit 4 for the storage battery. The storage battery 5 is made up of a secondary battery. The power charged in the storage battery 5 is output and used at night when the solar cell module 6 is not generating power, during a power outage, etc.

[0014] With the above configuration, DC power output from the power conversion circuit 7a connected to the solar cell module 6, the inverter 7b connected to the distribution board 8, or the power conversion circuit 4 connected to the storage battery 5 is supplied to the power conversion device 10. Each of the power conversion circuits 7a, 4, and the inverter 7b corresponds to an external device. In the power conversion device 10, the DC power supplied from the external device is converted by the power conversion circuit 21 into DC power required by the on-board battery 3, and then supplied to the on-board battery 3 via the vehicle-side power transmission cable 14, thereby charging the on-board battery 3. The electric vehicle 2 also corresponds to an external device. Instead of the distribution board 8, a power switchboard having a function of converting to an appropriate voltage may be provided.

[0015] FIG. 1B is a diagram showing the flow of current in a configuration diagram of the power conversion device 10. In FIG. 1B, arrows indicate the flow of current when DC power supplied from the house 1 is converted and then supplied to the vehicle 2. The power conversion device 10 includes a first filter substrate 17, a second filter substrate 18, and a power conversion unit 20 connected between the filter substrates 17 and 18, which are multiple electronic substrates provided inside a housing. Each of the filter substrates 17 and 18 has a filter circuit. For example, each of the filter substrates 17 and 18 has a plurality of common mode noise filters 17a and 18a connected in series.

[0016] The power conversion unit 20 has a power conversion circuit 21 including switching components having a plurality of switching elements such as transistors, MOS-FETs, IGBTs, etc., a reactor, a transformer, etc., and a control circuit board 23 that controls the switching of the power conversion circuit 21. The control circuit board 23 has a control circuit.

[0017] The power conversion circuit 21 has two power conversion boards and multiple magnetic components such as reactors and transformers. The power conversion boards have a power conversion circuit. In the example of FIG. 1B , the first filter board 17 operates as an input-side filter board that shapes DC power input from the outside and outputs it to the power conversion unit 20. The second filter board 18 operates as an output-side filter board that shapes DC power input from the power conversion unit 20 and outputs it to the outside. The power conversion unit 20 converts the DC power shaped by the first filter board 17 into DC power of a relatively high predetermined voltage, for example, 400 V. The power lines of the house-side power transmission cable 12 are connected to the external end of the first filter board 17. The power lines of the vehicle-side power transmission cable 14 are connected to the external end of the second filter board 18.

[0018] As a result, DC power supplied from house 1 to power conversion device 10 via house-side power transmission cable 12 is shaped by first filter substrate 17 and then converted to DC power of a predetermined voltage by power conversion unit 20. The converted DC power is shaped by second filter substrate 18 and then supplied to onboard battery 3 of electric vehicle 2 via vehicle-side power transmission cable 14, where it charges onboard battery 3. It is necessary to prevent noise generated by power conversion unit 20 from being transmitted to the outside via the power lines included in house-side power transmission cable 12 and the power lines included in vehicle-side power transmission cable 14. In FIG. 1B, the areas with solid ellipses indicate that noise is carried on the power lines, and this noise is shaped by each filter substrate 17, 18, while the areas with unfilled ellipses indicate that the noise has been removed. In the power conversion device 10, which is the device, in both a configuration in which current flows from the house to the vehicle and a configuration in which current flows from the vehicle to the house, each filter substrate 17, 18 prevents noise from flowing out to the outside.

[0019] On the other hand, when power charged in the on-board battery 3 is supplied to the storage battery 5 or power station 7 on the residential side via the power conversion unit 20, power conversion may be performed in the power conversion unit 20. In this case, the current flow is reversed from that in FIG. 1B . Specifically, DC power supplied from the electrically powered vehicle 2 side to the power conversion device 10 via the vehicle-side power transmission cable 14 is shaped by the second filter substrate 18 and then converted into DC power of a relatively low predetermined voltage by the power conversion unit 20. The converted DC power is shaped by the first filter substrate 17 and then transmitted to the residential side via the residential-side power transmission cable 12. In this case, the second filter substrate 18 operates as the input-side filter substrate, and the first filter substrate 17 operates as the output-side filter substrate.

[0020] The configuration of the power conversion device 10 will be described in more detail. The basic structure of the power conversion device 10 will be described with reference to Figs. 2 to 8. Fig. 2 is a perspective view of the power conversion device 10 as seen from the front side. Fig. 3 is a perspective view of the power conversion device 10 as seen from the rear side. Fig. 4 is a perspective view of the power conversion device 10 taken along line AA in Fig. 2. Fig. 5 is a perspective view of the power conversion device 10 taken along line BB in Fig. 2. Fig. 6 is a front view of the power conversion device 10 with the front side panels 30a, 40a and the terminal box cover 58 (Fig. 5) omitted. Fig. 7 is an exploded perspective view of the power conversion device 10. Fig. 8 is a perspective view of the terminal box 50 fixed to the lower end of the first housing portion 30 as seen from below.

[0021] 2 and 3, the power conversion device 10 includes a box-shaped housing 24 that is placed on the ground via thin, box-shaped legs 90 provided at the bottom and having flanges extending in the left and right directions, a vehicle-side power transmission cable 14 that is drawn out from inside the housing 24, and a vehicle-side connector 15 that is provided at the end of the vehicle-side power transmission cable 14. In the following description, the side of the housing 24 that corresponds to the front side in FIG. 1 is referred to as the front side, the opposite side is referred to as the rear side, and the right and left sides of the housing 24 when viewed from the front are referred to as the right and left sides, respectively. A display unit 26, shown in a dashed-dotted line frame in FIG. 2, is provided on a front surface 25 of the housing 24.

[0022] The display unit 26 displays the charging state and includes, for example, one or both of a liquid crystal display unit and a lighting display unit. In the drawings described below, the front side of the power conversion device 10 is indicated by an arrow Fr, the right side by an arrow Rh, and the top side by an arrow Up. A rectangular platform-shaped locking frame 27 into which the vehicle-side connector 15 is fitted and locked, and a hook portion 28 for hanging the wound vehicle-side power transmission cable 14 are provided on the outside of the right side of the housing 24. Note that the display unit 26 is not limited to being provided on the front surface 25, but can also be provided on either the left or right side of the housing 24. When the rear surface (the surface on which the first side panel 30d is located) is defined as the surface on which the air intake 24b for taking in cooling air from the outside is provided, as described below, the front surface of the housing 24 is the outer surface opposite the rear surface.

[0023] 3, an intake port 24b for taking in external cooling air is formed in the vertical middle of the first side panel 30d disposed at the rear end of the housing 24. An exhaust port 24c for discharging air that has become hot inside the housing 24 to the outside is formed in the upper part of the side panel 24a.

[0024] As shown in Figures 4 to 6, the housing 24 is constructed by stacking a first housing section 30 and a second housing section 40, which can be separated and independently of each other, vertically, and fastening the vertically stacked sections together on the inside with screws. The second housing section 40 is fixed to the underside of the first housing section 30. The first housing section 30 has a circuit component storage space 31 inside. The second housing section 40 has an installation space 41 inside. The "installation space 41" is a space for connecting the terminals of both the house-side power transmission cable 12 connected to the external house 1 side and the vehicle-side power transmission cable 14 connected to the vehicle 2 side.

[0025] The first housing unit 30 includes a first housing main body 32 (FIGS. 5 and 7) and multiple first side panels 30a, 30b, 30c, and 30d attached to the first housing main body 32 so as to cover the periphery of the first housing main body 32. As shown in FIG. 5, the first housing main body 32 includes a main body panel 80 that is elongated in the vertical direction, and an upper protruding plate portion 81 and a partition wall portion 82 fixed to both upper and lower ends of the main body panel 80 so as to protrude forward. The main body panel 80 corresponds to a main body component. The upper protruding plate portion 81 has wall portions 81a (FIG. 6) extending downward continuously in the circumferential direction from the front end and both left and right ends of its peripheral edge. The partition wall portion 82 has wall portions 82a (FIG. 6) extending upward from the front end and both left and right ends of its peripheral edge. The multiple first side panels may be detachably attached to the first housing main body 32 with screws.

[0026] As shown in FIG. 6, a metal plate 400 having an L-shaped cross section and elongated in the vertical direction and a rectangular metal plate 401 having an L-shaped cross section are disposed inside the first side panels 30a, 30b, 30c, and 30d to provide waterproof and dustproof functions for electronic components. An insulating sheet 402 having a generally U-shaped cross section and elongated in the vertical direction is disposed inside each of the metal plates 400 and 401. The insulating sheet 402 functions to protect the electronic circuit components from contact with the L-shaped metal plate 400 and the rectangular metal plate 401. Each of the first side panels 30a, 30b, 30c, and 30d is disposed outside the metal plates 400 and 401, and is a panel that provides design and simple waterproofing, more specifically, the function of preventing sideways rainwater from hitting the metal plates 400 and 401.

[0027] The second housing part 40 includes a second housing main body 42 (FIGS. 5 and 7) having an opening 43 (FIG. 7) at its front end. An installation side panel 40a is detachably attached to the front side of the second housing main body 42 by screws, covering the front opening 43. The opening 43 is also the front opening of the installation space 41. Therefore, the front opening of the installation space 41 can be opened and closed by the installation side panel 40a.

[0028] 4, through holes 190 are formed on both the left and right ends of the upper portion of the installation side panel 40a. The installation side panel 40a is detachably attached to the second housing body 42 by screws (not shown) that pass through each through hole 190 and a through hole formed in a terminal box 50 (described later) and are fastened to screw holes formed in the second housing body 42. The installation side panel 40a may also be fastened to the second housing body 42 by screws without using the terminal box 50.

[0029] A partition wall 82 is provided inside the housing 24, separating the interior of the housing 24 into a circuit component accommodating space 31 that is covered from the outside and accommodates electronic circuit components, and an installation space 41 that is covered from the outside and is used for connecting the terminals of the power transmission cables 12, 14 that are connected to external devices. The partition wall 82 is a bottom plate provided at the lower end of the first housing portion 30. The electronic circuit components include the first filter substrate 17, the second filter substrate 18, and electronic circuit components that constitute the power conversion unit 20 connected between the filter substrates 17, 18.

[0030] 5, a heat sink block 60, which is a first support member, and a cylindrical portion 70, which is disposed below the heat sink block 60, are disposed inside the first housing portion 30. As shown in FIG. 28, which will be described later, the cylindrical portion 70 is a metal portion formed by two second support members 71 and 72 on the left and right, a third support member 73 at the front end, and a main body panel 80 that constitutes the first housing main body 32.

[0031] Two power conversion boards 101, 102 are fixed to the left and right ends of the heat sink block 60, and a control circuit board 23 is fixed to the front end of the heat sink block 60. The power conversion boards 101, 102 are first electronic boards, and the control circuit board 23 is a fourth electronic board. Filter boards 17, 18, which are second electronic boards, are fixed to the outer surfaces of the left and right ends of the cylindrical portion 70, respectively, and a power supply circuit board 19, which is a third electronic board, is fixed to the outer surface of the front end of the cylindrical portion 70.

[0032] 7, a box-shaped terminal box 50 is fixed to the upper inside of the second housing 40. Inside the terminal box 50, a terminal block is housed, which is provided with connection parts between the terminals of the power transmission cables 12, 14 and the terminals of the wiring connected to the electronic circuit components.

[0033] As shown in FIG. 5, the heat sink block 60 includes a main body tubular portion 61 having a vertically long rectangular cylindrical shape, and an intake duct 62 fixed to the lower end of the main body tubular portion 61. The intake duct 62 has a lower end plate portion 62a at its lower end that slopes rearward. The intake duct 62 has openings at its rear and upper ends, and discharges air taken in through the intake port 24b upward. An air intake fan 63 is provided inside the rear end opening of the intake duct. The main body tubular portion 61 is made of metal, and the intake duct 62 is made of resin or metal. For example, the main body tubular portion 61 is integrally molded by metal extrusion molding.

[0034] A heat dissipation unit 64 is provided inside the cylindrical main body portion 61 of the heat sink block 60. The heat dissipation unit 64 has multiple heat transfer plates 65 arranged parallel to the front-to-rear direction. The temperature of the cylindrical main body portion 61 is reduced by heat exchange between the heat transfer plates 65 and the air passing between the heat transfer plates 65. An exhaust duct 191 is fixed to the upper part of the inside of the first housing portion 30, facing the upper opening of the cylindrical main body portion 61. The upper front end surface of the exhaust duct 191 is inclined toward the rear, and the lower and rear ends are open. An air exhaust fan 67 is provided inside the rear end of the exhaust duct, and its rear opening faces the exhaust port 24c. As a result, when each fan is driven, air flows inside the heat sink block 60, and this air cools the heat sink block 60 and the boards and electronic circuit components provided around the heat sink block 60. It is not necessary to provide both fans 63 and 67, and only one of the fan 63 on the upstream side of the heat sink block 60 in the air flow direction and the fan 67 on the downstream side may be provided in the power conversion device 10.

[0035] In order to remove noise generated in the power conversion unit 20, there is a possibility that noise may be carried on the power line of the first filter substrate 17 or the second filter substrate 18 on the input side. Meanwhile, the cylindrical portion 70 is made of metal, and as shown in FIG. 30 described later, two signal lines 97, 98, which are electric wires for communication, pass inside the cylindrical portion 70. Each of the signal lines 97, 98 is a harness that is led out from the inside of the cylindrical portion 70 and then connected to the control circuit board 23. One of the two signal lines 97, 98, the signal line 97, is connected to a control device in the house 1 and communicates between the control device and the control circuit board 23. For this reason, the signal line 97 is connected to a signal line 93 connected to the house side through a quick-connect terminal 96 for communication (FIG. 15) inside the terminal box main body 51 described later.

[0036] The other signal wire 98 of the two signal wires 97, 98 is included in the vehicle-side power transmission cable 14 and is connected to a signal wire connected to the vehicle-side connector 15 via parts of the female connectors 94a, 94b, 94c, and 94d provided in the terminal box 50. As a result, the signal wire 98 transmits information such as the connection state of the vehicle-side connector 15 with the vehicle to the control circuit board 23. Because the signal wires 97, 98 pass inside the metal tubular portion 70 as described above, noise from the filter substrates 17, 18 arranged outside the tubular portion 70 is blocked by the tubular portion 70, and noise can be prevented from being transmitted to the signal wires 97, 98 inside the tubular portion 70.

[0037] The second housing body 42 and terminal box 50 of the second housing unit 40 (FIG. 2) will be described using FIGS. 9 to 19. The second housing unit 40 includes the second housing body 42 and the terminal box 50 fixed to the inside of the upper part of the second housing body 42. As shown in FIGS. 2 to 6, the second housing unit 40 also has an installation side panel 40a detachably attached to the front side of the second housing body 42, and three second side panels 40b, 40c, and 40d attached to both left and right ends and the rear end. Each of the second side panels 40b, 40c, and 40d is fixed to the second housing body 42 with screws.

[0038] As shown in FIG. 3, the rear side of the second housing body 42 is covered by the lower end of the first side panel 30d, which covers the rear end of the first housing body 32 and extends downward to a position opposite the rear side of the second housing body 42, and the side panel 40d.

[0039] As shown in FIG. 11 , the second housing body 42 is formed by bending a metal plate material such as steel into a generally U-shaped cross section with an open front end. As a result, the second housing body 42 has rectangular frame portions 44, 45 provided on both left and right ends, and a rear end plate portion 46 connected to the rear ends of the two frame portions 44, 45. As shown in FIG. 19 , a rectangular through-hole 46a is formed on the underside of the rear end plate portion 46. As shown in FIGS. 11 and 19 , flanges 48a are provided on both left and right ends of a box-shaped recessed portion 47, and are fixed to the underside of the front side of the rear end plate portion 46 so as to close the front side of the through-hole 46a. A side plate portion 48b provided at the front end of the recessed portion 47 has a through-hole 48c formed therein, through which a PF pipe 500 ( FIG. 20 ) can pass, which houses the house-side power transmission cable 12 and the signal line 93 and ground line 92 ( FIGS. 13 and 15 ) that are communication lines. As described above, the second housing body 42 has two frame portions 44, 45 on both the left and right ends, which allows for a reduction in weight of the second housing body 42. Furthermore, when installation from the front side of the housing 24 is difficult, installation can be performed easily by inserting a hand from either the left or right direction. Furthermore, as shown in FIG. 20 (described later), installation can be performed easily when connecting the PF pipe 500, which houses the house-side power transmission cable 12, signal line 93, and earth wire 92 (FIGS. 13 and 15) inside, to the recessed portion 47.

[0040] The front end and both upper and lower ends of the outer periphery of each frame portion 44, 45 are provided with protruding portions that protrude toward the center in the left-right direction, and adjacent ends of the protruding portions are connected to form rigid, generally box-shaped legs 49a, 49b that are open toward the center in the left-right direction at each of the left and right ends of the second housing main body 42. As a result, an opening 43 that is open across the entire front end of the second housing main body 42 in the up-down direction is formed. In addition, the front end of a terminal box 50 (described later) is fixed across the two legs 49a, 49b.

[0041] The upper end of the rear end plate 46 of the second housing body 42, located between the two legs 49a, 49b, is bent downward at a right angle to form an upper end locking portion 42a. Two through holes 42c, one on each side, are formed in plate 42b extending downward from the front end of upper end locking portion 42a. Protrusions 57 provided on the rear end of terminal box 50 shown in FIG. 13 are inserted into and locked into each through hole 42c.

[0042] 12 to 14, terminal box 50 includes terminal box main body 51 shown in Fig. 14 and terminal box cover 58 shown in Fig. 12, which is detachable by being screwed and overlapped in the front-to-rear direction on the front end of terminal box main body 51. As a result, front box-side opening 52 (Fig. 14), which faces construction side panel 40a of terminal box main body 51, is closed by terminal box cover 58.

[0043] The terminal box body 51 has a box shape with a closed rear end and an upper end plate 53 at its upper end. As shown in FIGS. 10, 12, and 14, a plurality of through holes 53a and 53b are formed in the upper end plate 53. As shown in FIG. 10, the upper ends of a plurality of female connectors 94a, 94b, 94c, and 94d that form a first connection between the terminal of the vehicle-side power transmission cable 14 and the electronic circuit components in the first housing 30 protrude through the through hole 53a. As shown in FIG. 14, the through hole 53b is used to receive wiring connected to quick-connect terminals 95a and 95b for BUS connection that form a second connection between the terminal of the house-side power transmission cable 12 and the electronic circuit components in the first housing 30, as well as a quick-connect terminal 96 for communication (shown in FIG. 15). The female connectors 94a, 94b, 94c, and 94d are held by a plate (not shown) fixed to the upper side of the upper end plate 53.

[0044] 14, the terminal box body 51 has an open front end, and protruding portions 54 that protrude outward in the left-right direction are formed on both left and right ends of the front end. The left and right ends of a terminal box cover 58 are screwed to the protruding portions 54. In this state, the tip of each protruding portion 54 has an exposed portion 59 that protrudes further in the left-right direction than the left and right ends of the terminal box cover 58. Each exposed portion 59 overlaps the front end of the second housing body 42 and is screwed to it.

[0045] As shown in Fig. 14, a terminal block 51a with its front surface inclined downward toward the rear is provided at the upper inside portion of terminal box body 51. Quick-connect terminals 95a and 95b for BUS connection are held on the front surface of terminal block 51a so as to protrude downward. Furthermore, a bus bar 51d (Fig. 16) for connecting a ground wire is fixed to the front end of terminal block 51a.

[0046] 14 and 15, a cable support box 51b is provided at the lower inside of the terminal box main body 51. A fitting plate 51c that fits into and supports the vehicle-side power transmission cable 14 is fixed to the front of the cable support box 51b. A quick-connect terminal 96 for communication is provided on the outside of the side wall surface of the cable support box 51b. The quick-connect terminal 96 is connected to a signal line 97 that passes through the through-hole 53b of the upper end plate 53, the back side of the terminal box 50, and the inside of the cable support box 51b.

[0047] As shown in FIGS. 14 to 16 , a plurality of vertically extending grooves 111a, 111b, 111c, and 111d are formed in the lower edge of the front side surface of the terminal box body 51, which is the side surface of the installation side panel 40a. The grooves 111a, 111b, 111c, and 111d are adapted to fit the power transmission cables 12 and 14, the signal line 93, and the ground line 92. The ground line 92 is connected to the ground and is provided for grounding electronic components and the like within the first housing 30. Each of the grooves 111a, 111b, 111c, and 111d has a semicircular cross section. A strip-shaped packing 112 is attached to the lower edge of the front side surface of the terminal box body 51. The packing 112 is also attached to the inner surfaces of the plurality of grooves 111a, 111b, 111c, and 111d of the terminal box body 51.

[0048] 17 , a substantially rectangular cylindrical fitting tube portion 58a is formed on the rear side surface of the terminal box cover 58 to fit inside the opening of the terminal box main body 51. Furthermore, grooves 113a and 113b with semicircular cross sections are formed at the lower end of the fitting tube portion 58a and at the lower edge of the rear side surface of the terminal box cover 58 adjacent to the lower end at positions facing the multiple grooves 111a and 111b of the terminal box main body 51, for fitting the power transmission cables 12 and 14. Semicircular cross-sectional grooves 113c and 113d are formed at the lower end of the fitting tube portion 58a at positions facing the multiple grooves 111c and 111d of the terminal box main body 51, for fitting the signal wire 93 and the ground wire 92.

[0049] A strip-shaped packing 114 shown in Fig. 14 is attached to the lower edge of the rear side surface of the terminal box cover 58. The packing 114 is also attached to the inner surfaces of a plurality of grooves 113a, 113b, 113c, and 113d of the terminal box cover 58. Fig. 14 shows the packing 114 on the terminal box cover 58 side as being attached to the packing 112 on the terminal box main body 51 side, but in reality, the packing 114 on the terminal box cover 58 side is attached to the terminal box cover 58 in Fig. 17 (the same applies to Fig. 10).

[0050] 8 and 12 , with the terminal box cover 58 attached to the front surface of the terminal box body 51, packings 112 and 114 are interposed between the plurality of grooves 111a, 111b, 111c, 111d, 113a, 113b, 113c, and 113d and the power transmission cables 12 and 14, the signal wire 93, or the ground wire 92. This more reliably prevents foreign matter such as water from entering the terminal box 50 through gaps between the power transmission cables 12 and 14, the signal wire 93, and the ground wire 92 and between the terminal box cover 58 and the terminal box body 51 and the terminal box body 51.

[0051] 14 and 16, protrusions 115a, 115b, 115c, and 115d that protrude downward and have semicircular cross sections are formed on the lower peripheral edges of the plurality of grooves 111a, 111b, 111c, and 111d on the underside of the front end of the terminal box body 51. Flanges are formed at the tips of the protrusions 115a, 115b, 115c, and 115d. After the power transmission cables 12 and 14, the signal wire 93, and the ground wire 92 are fitted into the multiple grooves 111a, 111b, 111c, and 111d of the terminal box body 51 via the packings 112, wire bands (not shown) are fastened to the flanges of the protrusions 115a, 115b, 115c, and 115d until the terminal box cover 58 is fixed to the terminal box body 51. The wire bands fasten the power transmission cables 12 and 14, the signal wire 93, and the ground wire 92 to the inner surfaces of the protrusions. This prevents the power transmission cables 12, 14, etc. from slipping out of the terminal box body 51 until the terminal box cover 58 is fixed to the terminal box body 51.

[0052] 15 and 16 do not show the connections between the power transmission cables 12, 14, the signal line 93, and the ground line 92 and the wiring connected to the electronic circuit components. In reality, the home side power transmission cable 12 includes two power lines, which are led out from the ends of the insulating tube of the home side power transmission cable 12 inside the terminal box 50 and connected to quick-connect terminals 95a and 95b.

[0053] The signal line 93 is connected to a communication quick-connect terminal 96. The ground line 92 is connected from inside the first housing 30 to a bus bar 51d (FIG. 16) for connecting the ground line, which is inserted into the terminal box 50, through a slit 116 (FIG. 14) formed in the upper end plate 53 of the terminal box body 51.

[0054] Furthermore, male connectors (not shown) are connected to the terminals of the multiple wirings that extend from the end of the insulating tube of the vehicle-side power transmission cable 14 inside the terminal box 50. The multiple male connectors are connected to multiple female connectors 94a, 94b, 94c, and 94d that are fixed to the upper end of the terminal box 50. The multiple wirings with male connectors include two power lines and a communication signal line for checking the connection status with the vehicle, etc. As a result, the two power lines connected to the house are connected to the first filter substrate 17 inside the first housing 30, and the two power lines included in the vehicle-side power transmission cable 14 are connected to the second filter substrate 18 inside the first housing 30.

[0055] When the terminal box 50 is fixed to the second housing body 42 as shown in Fig. 9, as shown in Fig. 13, the multiple protrusions 57 formed on the rear end of the terminal box body 51 are inserted into and locked into the multiple through holes 42c of the second housing body 42 shown in Fig. 11. As shown in Fig. 13, the multiple protrusions 57 are formed by mountain-shaped protruding portions of two end side plate portions 117 that protrude rearward at two positions on the left and right at the upper part of the rear side surface of the terminal box body 51. Horizontal ribs 118 are connected to each end side plate portion 117 so as to intersect with them, and vertical ribs 119 are connected to the middle portions of the horizontal ribs 118 so as to intersect with them. This increases the rigidity of each protrusion 57.

[0056] With the protrusions 57 inserted and locked into the through-holes 42c, the rear side of the overhang 54 formed at the front end of the terminal box body 51 abuts against both left and right ends of the upper front side of the second housing body 42. In this state, the overhang 54 and both left and right ends of the upper front side of the second housing body 42 are screwed together. This secures the terminal box 50 across both left and right ends of the second housing body 42. Therefore, the second housing body 42 to which the terminal box is secured can have high rigidity against lateral movement, even though the front side of the second housing body 42 itself is open. At this time, the upper surfaces of the overhangs 130 formed at both left and right ends of the upper end of the terminal box body 51 (shown in FIG. 12 ) and overhanging in the left-right direction overlap the lower surfaces of the upper end plates of the legs 49a and 49b of the second housing body 42. This provides a more stable connection between the terminal box 50 and the second housing body 42.

[0057] As shown in FIG. 12 , a rectangular-frame packing 131 is attached to the periphery of the upper surface of the upper end plate 53 of the terminal box body 51, the portion of the upper surface that is exposed from the upper surface of the second housing body 42. When the upper surface of the second housing body 42 is abutted against the lower surface of the first housing body 32 and fixed, this packing 131 is compressed between the upper end plate 53 and the lower surface of the first housing body, sealing off the portion of the upper end plate 53, including the holes 53a and 53b, from the outside. In this state, the installation space 41 inside the second housing 40 and the circuit component housing space 31 inside the first housing 30 are closed by the partition wall 82, and are not communicated with except through the hole in the upper end plate 53. The hole in the upper end plate 53 can also be completely sealed by covering it with a sealant such as putty.

[0058] 16, gaskets 132a, 132b, and 132c are attached to both left and right ends of the periphery of the opening on the front side of the terminal box body 51 and to the front end of the partition wall 82 of the first housing body 32 so as to surround the opening of the terminal box body 51 at both left and right ends and the upper end of the periphery of the opening. These gaskets 132a, 132b, and 132c are arranged between the terminal box cover 58 and the terminal box body 51 and the partition wall 82 in FIGS. 12 and 17. As a result, together with the gasket 112 arranged at the lower end of the periphery of the opening of the terminal box body 51 shown in FIG. 14, the opening of the terminal box body 51 is sealed all around.

[0059] 18, a side panel 40d is fixed to the rear end of the second housing main body 42 so as to cover the rear side of the through-hole 46a (FIG. 19) of the rear end plate 46. The side panel 40d has a main body 132 arranged on the rear side of the second housing main body 42, and an end plate 133 bent at a substantially right angle along the front-to-rear direction on the right end of the main body 132. The end plate 133 abuts against the outer surface of the frame 45 at the right end of the second housing main body 42 and is screwed together.

[0060] 19, rectangular locking holes 134 are formed at two upper and lower positions adjacent to the left of the through-hole 46a in the rear end plate 46 of the second housing main body 42. Insertion plate portions (not shown) with a generally L-shaped cross section that protrude forward and then bend at a generally right angle toward the left are formed at two upper and lower positions on the left edge of the main body 132 of the side panel 40d. With the end plate portion 133 screwed to the frame portion 45 at the right end as described above, each insertion plate portion is inserted into and locked into the locking holes 134. Thus, when fixing the side panel 40d to the second housing main body 42, the left insertion portions are inserted into the locking holes 134, and then the end plate portion 133 at the right end is pressed against the frame portion 45 of the second housing main body 42, and the end plate portion 133 can be fixed to the frame portion 45 by screwing. Therefore, the side panel 40d can be attached to or detached from the second housing body 42 from the right side of the second housing body 42, even if there is not a large space behind the second housing body 42. The left-right positional relationship between the locking holes of the second housing body 42 and the screw joints of the second housing body 42 and the side panel 40d can also be reversed.

[0061] In the case of so-called underground wiring, in which the house-side power transmission cable 12 and signal wire 93 taken out from inside the house are passed underground and connected to predetermined positions inside the second housing unit 40, the house-side power transmission cable 12 and signal wire 93 are inserted into the inside of the second housing main body 42 from below the lower end of the second housing main body 42. In this case, as shown in FIG. 18, the through-hole 46a (FIG. 19) of the rear end plate 46 may remain covered by the side panel 40d.

[0062] On the other hand, in the case of so-called exposed wiring, in which the residential side power transmission cable 12 and signal line 93 are housed in a PF pipe 500 (Figure 20) without passing underground and connected to a predetermined position within the second housing part 40, the side panel 40d is removed from the second housing main body 42.

[0063] In this state, the through-hole 46a of the second housing main body 42 is exposed to the outside, as shown in Fig. 19. Therefore, as shown in Fig. 20, the PF pipe 500, inside which the house side power transmission cable 12 is housed, can be inserted from the outside to the inside of the second housing part 40 through the through-hole 46a of the second housing main body 42.

[0064] 20 , the PF pipe 500 extends in the left-right direction from one left-right side of the second housing body 42 and is bent at a relatively large arc-shaped bent portion 500a near the second housing body 42. Then, a portion of the PF pipe 500 located forward of the through hole 46a passes through a circular through hole 48c formed at the front end of a recessed portion 47 provided on the front side of the rear end plate portion 46 of the second housing body 42. More specifically, the recessed portion 47 is provided in the second housing portion 40 so as to be recessed forward, toward the installation space, from the rear end plate portion 46 into which the PF pipe 500 is inserted. The front end, which is the farthest end of the recessed portion 47, is formed with a through hole 48c through which the PF pipe 500 passes.

[0065] Fig. 21(a) is a cross-sectional view taken along CC in Fig. 20. As shown in Fig. 21(a), in the embodiment, the bent portion 500a of the PF pipe 500 can be inserted forward of the rear end of the second housing main body 42. Therefore, the portion of the PF pipe 500 extending in the left-right direction behind the second housing main body 42 can be brought closer to the rear end of the second housing main body 42. This eliminates the need to secure a large space behind the second housing part 40 for wiring the PF pipe 500.

[0066] 18, the rear side, which is the outside of the recessed portion 47, is covered by the side panel 40d attached to the second housing main body 42. Therefore, when the through holes 48c, 48d of the recessed portion 47 are not used, it is possible to prevent foreign matter from entering the inside of the second housing main body 40 from the outside through the through holes 48c, 48d.

[0067] On the other hand, FIG. 21(b) is a diagram corresponding to FIG. 21(a) of a power converter 10a of a comparative example. In the comparative example, the rear end plate 135 of the second housing body 42 has only a circular through-hole 135a formed therein, through which the PF pipe 500 can pass with almost no gap, and the rear end of the through-hole 135a substantially coincides with the rearmost end of the rear end plate 135 of the second housing body 42. In this comparative example, the arc-shaped bent portion 500a of the PF pipe 500 cannot be inserted forward of the rear end of the second housing body 42a. Therefore, the portion of the PF pipe 500 extending in the left-right direction behind the second housing body 42 is positioned farther rearward than the rear end of the second housing body 42. Therefore, in the comparative example, a large space must be secured behind the second housing portion for wiring the PF pipe 500.

[0068] 21(a), the portion of the PF pipe 500 extending in the left-right direction behind the second housing body 42 can be positioned closer to the rear end of the second housing body 42 by a distance d1 than in the comparative example. Therefore, in the embodiment, the separation distance from an obstacle such as a wall on the rear side of the power conversion device 10 can be reduced.

[0069] 22 , in this embodiment, the vehicle-side power transmission cable 14 is routed from the lower side of the terminal box 50 to the front side. This allows the vehicle-side power transmission cable 14 to have a relatively large arc-shaped curved portion 14a below the second housing 40. This prevents the vehicle-side power transmission cable 14 from being bent sharply inside the second housing 40, thereby improving the durability of the vehicle-side power transmission cable 14.

[0070] 20 and 21(a), when the house side power transmission cable 12 is inserted from the rear side of the second housing main body 42, the house side power transmission cable 12 is routed from the rear side to the front side below the terminal box 50. This allows the house side power transmission cable 12 to form a relatively large arc-shaped curved portion below the second housing 40, similar to the vehicle side power transmission cable 14 shown in FIG. 22, and prevents the house side power transmission cable 12 from being bent sharply inside the second housing 40. This improves the durability of the house side power transmission cable 12. Similarly, it also prevents the signal line 93 and the ground line 92 from being bent sharply, improving their durability.

[0071] 23 to 26, the support structure for the vehicle-side power transmission cable 14 relative to the second housing body 42 will be described. As shown in Fig. 23, the vehicle-side power transmission cable 14 is routed inside the second housing body 42 with its middle portion held by a clamp assembly 120 fixed to the underside of the left frame portion 44 of the second housing body 42.

[0072] In the assembled state of the power conversion device 10, side panels 40a, 40b, and 40c (FIGS. 2 and 3) are actually arranged on the outside of the front side surface and the left and right side surfaces of the second housing main body 42. At this time, the portion of the vehicle-side power transmission cable 14 that passes from the outside through a through-hole formed in the second side panel 40c arranged on the left side of the second housing main body 42 is supported by the second housing main body 42 via the clamp assembly 120.

[0073] Specifically, as shown in Fig. 24 , a substantially rectangular through hole 136 is formed on the inside of the left frame portion 44 of the second housing main body 42. Furthermore, a hole-side recess 137 that is recessed toward the outside of the periphery of the through hole 136 is formed on part of the edge of the through hole 136. In Fig. 24 , the hole-side recess 137 is formed at the lower end of the through hole 136, but it may be formed at another position on the periphery of the through hole 136. With the longitudinal intermediate portion of the vehicle-side power transmission cable 14 held inside the clamp assembly 120, the clamp assembly 120 is fitted into and fixed in the hole-side recess 137.

[0074] As shown in Figures 25 and 26, the clamp assembly 120 is formed by combining two recessed components 121, 122, each having a C-shaped cross-section of the clamp-side recesses 121a, 122a on one side. Each recessed component 121, 122 has a block-shaped main body 123 having a C-shaped cross-section of the clamp-side recesses 121a, 122a on its side, a locking piece 124 extending laterally from one end of the main body 123 in the vertical direction, and a locking groove 125 formed on the side of the main body 123 opposite the locking piece 124 in the vertical direction. Each recessed component 121, 122 is made of resin or the like. The vertical positional relationship between the locking piece 124 and the locking groove 125 is opposite between the two recessed components 121, 122.

[0075] A protrusion 126 protrudes vertically from the tip of the locking piece 124 for locking into the locking groove 125 of the mating recessed components 122, 121. The main body 123 has a fixing piece 127 extending laterally at the end opposite the clamp-side recesses 121a, 122a. The fixing piece 127 has a through-hole 128 formed in it for screwing into the frame 44 of the second housing main body 42. A C-shaped wall 129 protrudes from one of the outer surfaces of each recessed component 121, 122 around the opening periphery of the clamp-side recesses 121a, 122a, and the clamp-side recesses 121a, 122a are also formed continuously on the inner surface of the wall 129. This increases the support strength for the vehicle-side power transmission cable 14 without increasing the overall thickness of the main body 123.

[0076] As shown in FIG. 25 , the two recessed components 121, 122 are arranged so that their clamp-side recesses 121a, 122a face each other, and then, as shown in FIG. 24 , they are combined so that the longitudinal middle portion of the vehicle-side power cable 14 is sandwiched between the clamp-side recesses 121a, 122a. When combined, the two clamp-side recesses 121a, 122a form a cylindrical hole. At this time, the protrusions 126 of the locking pieces 124 are engaged with the locking grooves 125 of the mating recessed component, applying a compressive force to the vehicle-side power cable 14 from the two recessed components 121, 122 and clamping the vehicle-side power cable 14. As a result, the vehicle-side power cable 14 is sandwiched between the clamp-side recesses 121a, 122a of the recessed components 121, 122, and the vehicle-side power cable 14 is held in the clamp assembly 120.

[0077] In this state, the main body 123 of the clamp assembly 120 is fitted into the hole-side recess 137 of the frame 44 of the second housing body 42, a bolt is passed through the through hole 128 of the fixing piece 127 and the through hole formed in the frame 44, and the bolt is tightened with a nut, thereby screwing the clamp assembly 120 to the second housing body 42. This increases the support strength of the vehicle-side power transmission cable 14, and therefore increases the strength of the vehicle-side power transmission cable 14 against pulling.

[0078] Since the clamp assembly 120 includes two recessed components 121, 122, workability is improved and costs are reduced. Specifically, unlike the embodiment, a clamp that holds the vehicle-side power cable may be constructed using a simple clamp component with a hole, rather than two separate components. However, with this configuration, passing the vehicle-side power cable 14 through the clamp component with a hole requires first removing the vehicle-side power cable 14 from the terminal and then inserting the end of the vehicle-side power cable 14 into the hole in the clamp component. This reduces workability, and when selecting the right or left insertion position of the vehicle-side power cable 14 relative to the housing of the power converter depending on the installation situation of the user of the power converter, the only option is to remove the vehicle-side power cable 14 from the terminal before installation. This configuration is undesirable due to its poor workability. To solve this problem, the embodiment employs a structure in which the clamp assembly 120 can be separated into two recessed components 121, 122, left and right, as described above. Furthermore, in this embodiment, not only is the clamp assembly 120 separable into two recessed parts 121 and 122, but the two recessed parts 121 and 122 are symmetrical in shape. This allows each of the recessed parts 121 and 122 to be produced using a single mold. Therefore, by using the clamp assembly 120, it is possible to improve workability and reduce costs.

[0079] 23 , the clamp assembly 120 is fixed to the right frame 45 of the second housing main body 42 in the same manner as the left frame 44. Therefore, the vehicle-side power transmission cable 14 may be led out from the right side of the second housing main body 42 while being held by the right clamp assembly 120. In this case, a locking frame for fitting and locking the vehicle-side connector 15 and a hook for hooking the wound vehicle-side power transmission cable 14 may be provided on the outside of the left side surface of the housing 24 of the power conversion device 10. Furthermore, because the clamp assembly 120 can be separated into left and right halves, the vehicle-side power transmission cable 14 can be positioned on either the left or right side of the housing of the power conversion device during installation without having to detach the vehicle-side power transmission cable 14 from the terminal.

[0080] Two clamp assemblies 120 do not need to be fixed to the second housing body 42 at the same time, and only the clamp assembly 120 holding the vehicle-side power transmission cable 14 may be fixed to the second housing body 42. Furthermore, by making the rear end plate 46 of the second housing body 42 a frame to which the clamp assembly 120 can be fixed, the vehicle-side power transmission cable 14 held by the clamp assembly 120 may be led outward from the rear side of the second housing body 42. In this way, it becomes easier to freely set the position at which the vehicle-side power transmission cable 14 is led outward from the second housing body 42.

[0081] As shown in FIGS. 4 and 6 above, the housing 24 has the circuit component housing space 31 and the installation space 41 separated by a partition wall 82, and the housing 24 includes an installation side panel 40a that can open and close the front opening 43 (FIG. 7) of the installation space 41. This allows the terminals of the power transmission cables 12, 14 to be connected to the terminals of the wiring connected to the electronic circuit components within the installation space 41 by opening the installation side panel 40a. Furthermore, since there is no need to open the circuit component housing space 31 in which the electronic circuit components are located during installation, foreign matter can be prevented from entering the circuit component housing space 31. Furthermore, there is no need to provide a cover that houses the connection portion of the terminal of the power transmission cable so as to protrude outward from the side of the housing. This prevents the installed power conversion device 10 from looking bad and reducing installation flexibility.

[0082] For example, when installing the power conversion device 10, the power conversion device 10 is installed in a predetermined outdoor position before the power transmission cables 12, 14 are connected. To connect the terminals of the power transmission cables 12, 14, the installation side panel 40a is removed from the state shown in FIG. 2 to expose the front opening 43 of the installation space 41, which is the interior space of the second housing body 42. At this time, the installation side panel 40a may be removed in advance during installation. Furthermore, the terminal box cover 58 arranged in the installation space 41 is removed from the terminal box body 51, and the terminals of the power transmission cables 12, 14 are connected inside the terminal box body 51. Furthermore, the terminal of the communication signal line 93 is connected to the communication quick-connect terminal 96, and the ground wire 92 is connected to the bus bar 51d.

[0083] In this example, the connection portions of the power transmission cables 12, 14, the signal line 93, and the earth line 92 are arranged inside the terminal box 50, and therefore the connection portions are covered by the double structure of the terminal box 50 and the second housing part 40. Therefore, the terminal box 50 is not directly affected by wind and rain, and therefore problems in the performance and durability of the power conversion device 10 can be suppressed even if the waterproofing treatment of the terminal box 50 is simple.

[0084] The second housing part 40 also includes a second housing main body 42 having a front opening 43, and the installation side panel 40a is detachably attached to the second housing main body 42 and covers the opening 43. This makes it possible to ensure waterproofing and dustproofing of the inside of the installation space 41 with a simpler structure using screws, unlike a configuration in which the installation side panel 40a is attached to the second housing main body 42 using a hinge or the like to open and close the opening.

[0085] As another example of the embodiment, the installation side panel 40a can be integral with the first side panel 30a of the first housing unit 30. Even in this case, metal plates 400, 401 (see FIG. 7) for protecting the components arranged inside the first housing unit 30 from external foreign matter can be provided inside the first side panel 30a, thereby preventing foreign matter from entering the circuit component housing space 31. The right side panels 30b, 40b or the left side panels 30c, 40c can also be integral with each other.

[0086] As another example of the embodiment, the second housing may be disposed above the first housing, and a terminal box may be disposed inside the second housing, accommodating a terminal block provided with a connection portion for the terminal of the power transmission cable. This allows the connection portion for the vehicle-side power transmission cable to be provided on the upper side, thereby improving the flexibility of product design.

[0087] Furthermore, a terminal box accommodating a terminal block provided with a connection portion is disposed inside the second housing portion 40, and the terminal box may have an opening facing either the left or right side when the housing is viewed from the outside, facing the front surface, which is the outer surface opposite the back surface. This allows an installation side panel that covers the opening of the second housing portion to be provided at one of the left and right end of the housing, thereby improving the degree of freedom in product design.

[0088] Furthermore, by making all of the side panels that cover the entire outer periphery of the second housing body 42 out of metal, it is possible to improve the electromagnetic shielding against noise inside the terminal box 50. In this case, by making all of the side panels that cover the entire outer periphery of the first housing body 32 out of metal, it is possible to further improve the electromagnetic shielding against noise of the electronic components that make up the power conversion device 10.

[0089] Furthermore, a terminal box accommodating the terminal block may be disposed inside the second housing 40, and the terminal box may be configured to include a metal terminal box body and a metal terminal box cover that closes the opening of the terminal box body. In this case, the electromagnetic shielding against noise within the terminal box can be improved. In this case, too, by making all of the side panels that cover the entire outside periphery of the first housing body out of metal, the electromagnetic shielding against noise of the electronic components that make up the power conversion device 10 can be further improved.

[0090] In this example, construction space 41 is a space for connecting the terminals of both house-side power transmission cable 12 connected to the house side and vehicle-side power transmission cable 14 connected to the vehicle side. When construction space 41 is a space for connecting the terminals of both house-side power transmission cable 12 and vehicle-side power transmission cable 14 as in this example, it is not necessary to connect electronic components inside the first housing unit to vehicle-side power transmission cable 14 indoors in advance, and then, with the first housing unit sealed, carry the vehicle-side power transmission cable 14 and the housing together outdoors and install them in a predetermined position. This reduces the burden on the worker and makes construction work easier.

[0091] Next, a structure that prevents noise from being carried on the signal lines and a structure that facilitates assembly of parts will be described. As shown in Fig. 27, with the peripheral side panels removed from the power conversion device 10, a heat sink block 60, which is a first support member, is fixed to a main body panel 80 that is long in the vertical direction and that constitutes the first housing main body 32, and a cylindrical portion 70 is provided below the heat sink block 60.

[0092] As shown in FIGS. 27 to 29, the cylindrical portion 70 has two second support members 71, 72 and a third support member 73 fixed to the tip of each of the second support members 71, 72, forming an inner space 138 (FIG. 29) surrounded by the cylindrical portion 70. Specifically, the second support members 71, 72, which are two intermediate support members, are fixed to the front side, which is the inner surface of the main body panel 80, so as to protrude toward the front, which is the same side. Furthermore, a third support member 73, which is a tip support member, is fixed to the tips of the two second support members 71, 72. The two second support members 71, 72 support filter boards 17, 18, which are intermediate electronic boards. The third support member 73 supports a power circuit board 19, which is a tip electronic board. The second support members 71, 72, the third support member 73, and the main body panel 80 together form the cylindrical portion 70, which has a rectangular cross section and is made of metal such as steel plate. This makes the inner space 138 of the cylindrical portion 70 a space that is less susceptible to external electromagnetic noise.

[0093] 30 and 31 , a supercapacitor 140, which is an electronic component, is disposed in the inner space 138. Furthermore, signal lines 97, 98, which are two communication lines connected to the control circuit board 23, run through the inner space 138. Each of the signal lines 97, 98 includes a signal line 97 connected to a device on the home side and the control circuit board 23, and a signal line 98 connected to the vehicle side power transmission cable 14 and the control circuit board 23. As a result, the cylindrical portion 70 makes each of the signal lines 97, 98 less susceptible to the effects of external electromagnetic noise.

[0094] As shown in FIG. 28, the heat sink block 60, the second support members 71 and 72, and the third support member 73 are fixed to a main body panel 80.

[0095] 32 to 35, a first assembly A1 is formed by a heat sink block 60 and power conversion boards 101 and 102, which are first electronic boards supported on both the left and right sides of the heat sink block 60. The first assembly A1 also includes a first magnetic component 150 and a second magnetic component 151 attached to the left side of the heat sink block 60, and a third magnetic component 152 attached to the right side of the heat sink block 60. FIGS. 32 and 33 show a state in which a filter 192 is disposed opposite the intake port of the intake duct 62 of the heat sink block 60.

[0096] 36 and 37, the left second support member 71 and the first filter board 17, which is the second electronic board, supported by the second support member 71 constitute a left second assembly A2a. As shown in FIGS. 36 and 38, the right second support member 72 and the second filter board 18, which is the second electronic board, supported by the second support member 72 constitute a right second assembly A2b. As shown in FIG. 36, the third support member 73 and the power supply circuit board 19, which is the third electronic board, supported by the third support member 73 constitute a third assembly A3.

[0097] 27 and 28, the first assembly A1, the two second assembly bodies A2a and A2b, and the third assembly body A3 are fixed to a main body panel 80 that constitutes the housing 24. At this time, the third assembly body A3 is fixed to the main body panel 80 via the second assembly bodies A2a and A2b. This facilitates the assembly of parts.

[0098] Furthermore, a fourth assembly A4 is fixed to the front side of the heat sink block 60. The fourth assembly A4 includes a fourth support member 74 and a control circuit board 23, which is a fourth electronic board, supported by the fourth support member 74. The fourth assembly A4 is fixed to the main body panel 80 via the heat sink block 60. This also facilitates the assembly of parts.

[0099] The second assemblies A2a and A2b, the third assembly A3, and the fourth assembly A4 will be described in detail using Figures 36 to 38. As shown in Figure 36, the second support members 71 and 72, the third support member 73, and the fourth support member 74 that respectively constitute the second assemblies A2a and A2b, the third assembly A3, and the fourth assembly A4 are each shaped like a plate that is long in the left-right direction of Figure 36, which corresponds to the up-down direction when the power conversion device is installed.

[0100] As shown in Figure 37, the left-hand second support member 71 is formed from a metal plate and has a rectangular, flat main body plate portion 71a that is long in the left-right direction in Figure 37, and two first fixing pieces 71b that are formed on both longitudinal sides of the rear end of the main body plate portion 71a and are bent in opposite directions at approximately right angles to each other. The right-hand fixing piece is not shown in Figure 37.

[0101] Additionally, a second fixing piece 71c is provided at the front end of the main body plate portion 71a, bent at a substantially right angle to the left, outside the tubular portion 70. A recess 71d is formed in the longitudinal middle of the front end of the main body plate portion 71a, and a harness clamper 160 is attached to fit into the recess 71d. The harness clamper 160 is provided to allow the harness to pass through the thickness direction of the second support member. Due to the presence of the recess 71d, the second fixing piece 71c is discontinuous at its longitudinal middle. Both longitudinal ends of the second fixing piece 71c protrude further outside the tubular portion 70 than the other longitudinal portions, and each has a through-hole formed therein for passing a screw therethrough. The second fixing piece 71c is used to screw the third support member 73 of the third assembly A3.

[0102] The first filter substrate 17 is supported on the left side of the main body plate portion 71a. A substrate 141 on which a supercapacitor 140 is provided is supported on the right side of the main body plate portion 71a. This forms a second assembly A2a. The supercapacitor 140 is used as a power storage unit connected to, for example, a power supply circuit board 19. Wiring connected to the supercapacitor 140 is taken out to the outside of the tubular portion 70 through a harness clamper 160 attached to the second support member 71.

[0103] As shown in Figure 38, the second support member 72 on the right side is formed from a metal plate and has a rectangular main body plate portion 72a that is long in the left-right direction of Figure 38, and two first fixing pieces 72b, 72c formed on both longitudinal sides of the rear end of the main body plate portion 72a and bent in opposite directions at approximately right angles to each other.

[0104] Additionally, a second fixing piece 72d is provided at the front end of the main body plate portion 72a, bent at a substantially right angle toward the outside of the tubular portion 70. Both longitudinal ends of the second fixing piece 72d protrude further to the right, that is, toward the outside of the tubular portion 70, than the other longitudinal portions, and each has a through-hole formed therein for passing a screw therethrough. The second fixing piece 72d is used to screw and fix the third support member 73 of the third assembly A3.

[0105] The second filter substrate 18 (FIG. 36) is supported on the right side of the main body plate portion 72a. A plurality of harness clampers 161 are attached to the left side of the main body plate portion 72a. Each harness clamper 161 is made of resin and has a generally rectangular frame shape with a locking portion 162 on one side for locking onto the main body plate portion 72a. Each harness clamper 161 is provided to pass through and guide and support the signal wire 97 or 98 passing inside the cylindrical portion 70. This forms the second assembly A2b.

[0106] As shown in Figure 36, the third support member 73 is formed from a metal plate and includes a main body plate portion 73a in the shape of a rectangular flat plate that is elongated in the left-right direction in Figure 36, and a wall portion 73b formed on the periphery of the main body plate portion 73a so as to extend forward except for a portion. Harness clampers 163 are attached to multiple positions on the wall portion 73b to pass harnesses through the thickness of the wall portion 73b. A power supply circuit board 19 is attached to the front side of the third support member 73, which is the upper side in Figure 36. This forms the third assembly A3.

[0107] As shown in FIG. 36, the fourth support member 74 is formed in the same manner as the third support member 73. In the fourth support member 74, like the third support member 73, a wall portion 74b is provided on the periphery of the main body plate portion 74a, extending forward except for a portion. Harness clampers 163 are attached to multiple positions on the wall portion 74b to pass the harness through in the thickness direction of the wall portion 74b. A control circuit board 23 is attached to the front side of the fourth support member 74, which is the upper side in FIG. 36. This forms a fourth assembly A4.

[0108] When the first assembly A1, the second assemblies A2a and A2b, the third assembly A3, and the fourth assembly A4 are fixed to the first housing main body 32, the first housing main body 32 is placed on the upper surface of a fixed stand such as a desk with the rear end of the first housing main body 32 facing downward, as shown in Fig. 28. Then, the first assembly A1 and the second assemblies A2a and A2b are moved from above so that they are placed on the main body panel 80 of the first housing main body 32, and assembled to the main body panel 80.

[0109] When the power converter 10 is installed, handles 66 are fixed with screws at two positions on the top surface of the heat sink block 60, which serves as the front side. As shown in FIG. 35 , the handle 66 includes a fixing piece 66a that fixes the heat sink block 60, a protruding plate portion 66b that protrudes forward, and a gripping piece 66c that is bent at a substantially right angle from the tip of the protruding plate portion 66b toward the opposite side from the fixing piece 66a. The left and right ends of the gripping piece 66c protrude from both left and right sides of the heat sink block 60, making the gripping piece 66c longer in the left-right direction. The handle 66 is provided so that an assembly worker can grasp it with their hands during assembly. Screw holes are formed at multiple positions on the gripping piece 66c of the handle 66. In the fourth assembly A4, screws that pass through through holes formed in the main plate portion of the fourth support member 74 are fastened to the screw holes in the gripping piece 66c. As a result, the fourth assembly A4 is fixed to the first assembly A1 via the handle 66.

[0110] 39 to 42, a configuration for fixing the first assembly A1 to the main body panel 80 constituting the first housing main body 32 will be described. In the first assembly A1, as shown in FIGS. 32 and 33, power conversion boards 101 and 102 are supported on both left and right side surfaces of the heatsink block 60. A first magnetic component 150 and a second magnetic component 151 are screwed to the left side surface of the heatsink block 60, and a third magnetic component 152 is screwed to the right side surface of the heatsink block 60. As a result, the heatsink block 60, with electronic components attached, is assembled to the housing 24. Therefore, after the electronic components are attached to the heatsink block 60, the heatsink block 60 can be assembled to the housing 24, which simplifies the assembly of the electronic components and improves production efficiency. Furthermore, the heatsink block 60 can efficiently cool the magnetic components 150, 151, and 152, which are heat-generating elements.

[0111] 32 and 33, hooks 68 are fixed with screws to protrude in the left-right direction from the outer surface of the heat sink block 60 at four positions, two positions on each of the rear ends of the left and right sides of the heat sink block 60. Each hook 68 has a locking portion 69 for hooking onto a cylindrical portion 84 (FIGS. 40 to 42) that is integrally formed on the housing 24.

[0112] The multiple cylindrical portions 84 are fixed by welding or the like, with, for example, a cylindrical pin having a flange penetrating from the rear surface of the main body panel 80 toward the front, and the flange abutting against the rear surface of the main body panel 80. Furthermore, a screw hole is formed on the inner surface of the cylindrical portion 84. Each hook portion 68 is a fixing metal fitting attached to the outer surface of the main body cylindrical portion 61 as a separate part from the main body cylindrical portion 61 of the heat sink block 60. Each hook portion 68 has a through hole 68a through which the screw shaft of a screw (not shown) that connects to the screw hole provided in the cylindrical portion 84 passes. In this example, the heat sink block 60 is fixed in a hooked state to the housing 24 using each hook portion 68.

[0113] FIG. 39 shows a state in which only the first assembly A1, of the first, second, third, and fourth assemblies A1, A2a, A2b, A3, and A4, is fixed to the main body panel 80. To fix the first assembly A1 in the state shown in FIG. 39, a stepped portion of the main body panel 80 is utilized. Specifically, as shown in FIG. 40, a protrusion 85 with a rectangular cross section is formed in the center of the front side of the main body panel 80 in the left-right direction. The protrusion 85 extends over the entire vertical direction of the main body panel 80 when installed. As a result, the left and right ends of the protrusion 85 form a stepped portion 86 with a generally L-shaped cross section that extends linearly in the vertical direction on the front side of the main body panel 80. The hook portion 68 is guided and slid along the side of the stepped portion 86, allowing the heat sink block 60 to be attached to a bottom surface 87, which is a fixing surface adjacent to the stepped portion 86.

[0114] When fixing the heat sink block 60 to the main body panel 80, first, as shown in FIGS. 40 and 41 , the heat sink block 60 is placed on the front surface of the main body panel 80. In this case, each hook 68 is positioned above the cylindrical portion 84 protruding from the front surface of the main body panel 80 in the installed state, i.e., on the right side in FIG. 40 . Then, by moving the heat sink block 60 in the direction of arrow β in FIG. 41 , the hook 68 slides along the stepped portion 86, and the cylindrical portion 84 engages with the locking portion 69 of each hook 68, as shown in FIG. 42 . At the same time, a screw is inserted through the through hole 68 a from the front surface of the hook 68 and is fastened to the screw hole in the cylindrical portion 84, with the head of the screw contacting the periphery of the through hole 68 a on the front surface of the hook 68 to fix it. 41 and 42 show the case where the cylindrical portion 84 is locked to one of the hook portions 68, but the remaining hook portions 68 are also locked to the cylindrical portions at the same time. As a result, the heat sink block 60 is fixed to the bottom surface 87 of the main body panel 80.

[0115] It is also possible to attach substrates to both the left and right side surfaces of the heat sink block 60 after the heat sink block 60 is fixed to the main body panel 80. However, in this case, as shown in FIG. 40 , if a standing wall 88 is provided by bending forward at the left and right ends of the main body panel 80, there is a possibility that interference will occur between the substrate and the standing wall 88 when viewed from the left and right. This may limit the positions at which screws can be fastened to the substrate. According to the embodiment, the heat sink block 60 is fixed to the main body panel 80 with the power conversion boards 101, 102 supported on both the left and right sides of the heat sink block 60. This further simplifies the assembly process.

[0116] As described above, in the embodiment, the heat sink block 60 is provided, which includes the main body tubular portion 61 having a heat dissipation portion on the inside, and the heat sink block 60 is fixed in a hooked state to the main body panel 80, which is a component of the housing 24. This allows the heat sink block 60, which is a heavy object, to be fixed to the housing 24 without using a large number of screws. This makes it easier to fix the heat sink block 60.

[0117] Furthermore, in the above description, the heat sink block 60 is fixed to the main body panel 80 while the main body panel 80 is laid down. However, as shown in FIG. 39 , the heat sink block 60 can also be attached to the main body panel 80 with the second housing body 42 fixed to the main body panel 80 and the main body panel 80 standing upright with the second housing body 42 facing downward, similar to the installation state of the power converter. In this case, the hooks 68 fixed to the heat sink block 60 are disposed on the upper side of each cylindrical portion 84 provided on the main body panel 80, and the hooks can be slid downward along the stepped portions 86 to hook the hooks onto the cylindrical portions 84. In this state, the heat sink block 60 can be fixed to the main body panel 80 by fastening screws to the screw holes formed in the cylindrical portions 84. By hooking the hooks 68 in this manner, the heat sink block 60 can be positioned properly, and even after fixation, the load is distributed by the screws and the hooks, improving the fixing strength of the heat sink block 60.

[0118] The heat sink block 60 is provided with a hook portion 68 that protrudes from the outer surface of the heat sink block 60. The hook portion 68 has a through hole 68a, and a screw that passes through the through hole 68a is coupled to a screw hole provided in the cylindrical portion 84 of the housing 24, thereby screw-coupling the heat sink block 60 to the main body panel 80. This allows positioning, hooking, and screw-fixing to be performed using a common part, thereby reducing the number of parts. As another example configuration, a part for screw-coupling the heat sink block to the main body panel may be provided in a position on the main body panel separate from the part for hooking the heat sink block.

[0119] Furthermore, the hook portion 68 is a fixing metal fitting attached to the main body tubular portion 61 of the heat sink block 60 as a separate part from the main body tubular portion 61. This makes it easy to freely set the number and position of the hook portion 68 relative to the heat sink block 60, which is a heavy object, thereby improving the degree of freedom in the layout of components inside the power conversion device.

[0120] Furthermore, the intake duct 62 fixed to the heat sink block 60 can be made of metal. In this case, it is possible to prevent the influence of noise on the signal lines inside the housing 24 through the intake port 24b provided in the housing 24. This improves the shielding performance against noise.

[0121] Furthermore, since the heat sink block 60 is provided with the handle 66, it is possible to improve the workability of attaching the heat sink block 60 to the housing 24. Furthermore, since the handle 66 can be used as a support for attaching the fourth assembly A4, which is another assembly, it is possible to reduce the number of dedicated parts for the support.

[0122] Next, as shown in Fig. 28, a method of assembling the second assemblies A2a, A2b, the third assembly A3, and the fourth assembly A4 to the main body panel 80 will be described. As shown by the direction of arrow α in Fig. 28, the second assemblies A2a, A2b, and the third assembly A3 are each moved downward in Fig. 28, and the second assemblies A2a, A2b are placed on top of the main body panel 80. Then, by engaging screws from top to bottom into the screw holes, the second assemblies A2a, A2b can be fixed to the main body panel 80.

[0123] Specifically, each second support member 71, 72, with electronic components such as a circuit board and a supercapacitor attached, is attached to the upper surface of a main body panel 80, which is laid flat on a fixed surface such as a desk. In this case, the second support members 71, 72 are arranged from top to bottom so as to be approximately perpendicular to the main body panel 80, and are screwed to the main body panel 80 from above using screws that pass through the holes in the first fixing pieces 71b, 72b, and 72c of each second support member 71, 72. Since the screws can be tightened from top to bottom, assembly is easy. On the other hand, tightening the screws horizontally requires inserting a screwdriver horizontally into the head of the screw, which reduces workability. This embodiment does not have this drawback.

[0124] 31 shows the state in which the second assemblies A2a and A2b are fixed to the main body panel 80, as viewed from the front during installation. One second support member 72 of the two second support members 71 and 72 is fixed to the main body panel 80 by tightening screws (not shown) located at the positions indicated by arrows P1 to P5 in FIG. 31 from top to bottom. This makes it easy to fix the second support member 72. The other second support member 71 can also be easily fixed to the main body panel from above with screws, just like the one second support member 71.

[0125] When the third assembly A3 is fixed to the upper ends of the two second assemblies A2a and A2b, two portions located in the left-right middle of the main body plate portion 73a of the third support member 73 contact the second fixing pieces 71c and 72d at the upper ends of the two second support members 71 and 72. In this state, the second support members 71 and 72 are fixed to the third support member 73 by screws passing through the through holes in the main body plate portion 73a and the second fixing pieces 71c and 72d and nuts fastened to the screws. In this state, the metal cylindrical portion 70 having a rectangular cross section is formed. As shown in FIG. 30 above, two signal wires 97 and 98 are arranged inside the cylindrical portion 70, and each signal wire 97 and 98 is supported by a harness clamper 161 attached to the second support member 72. As a result, the cylindrical portion 70 makes the signal lines 97 and 98 less susceptible to the effects of external electromagnetic noise.

[0126] Furthermore, when fixing the fourth assembly A4 to the heat sink block 60, two central portions of the main body plate portion 74a of the fourth support member 74 in the left-right direction are brought into contact from above with the upper surfaces of the handles 66 of the heat sink block 60. In this state, the fourth support member 74 and the heat sink block 60 are fixed together with screws that pass through the through-holes of the main body plate portion 74a and the handles 66 and nuts that are coupled to the screws. As a result, from the state shown in FIG. 36 , the two second assemblies A2a and A2b, the third assembly A3, and the fourth assembly A4 are fixed to the main body panel 80.

[0127] As described above, the first assembly A1, the second assembly A2a, A2b, and the third assembly A3 are fixed to the main body panel 80. The first assembly A1 also includes a heat sink block 60 including a cylindrical main body portion 61 with a heat dissipation portion on the inside, and power conversion boards 101, 102, which are multiple electronic boards supported on multiple outer surfaces of the heat sink block 60. This improves heat dissipation efficiency through a three-dimensional heat dissipation structure, and allows multiple electronic boards to be easily attached to the heat sink block 60 before fixing the heat sink block 60 to the main body panel 80. Furthermore, for each of the second assembly A2a, A2b, and the third assembly A3, the electronic boards can be attached to the support members 71, 72, and 73 before the assembly is mounted to the main body panel 80. This improves assembly efficiency.

[0128] Furthermore, since the third assembly A3 is fixed to the main body panel 80 via the two second assemblies A2a and A2b, the fixing structure of the second assemblies A2a and A2b can be made more stable.

[0129] Next, the connections and arrangement of the electronic components inside the power converter will be described in more detail. In Figure 43, the members on which the boards are supported are indicated in parentheses. As shown in Figure 43, the multiple boards 17, 18, 19, 23, 101, and 102 are electrically connected by harnesses 170, which are multiple wirings, between boards adjacent to each other in the circumferential direction of the cylindrical portion 70 or heat sink block 60, or between boards adjacent to each other in the longitudinal direction of the cylindrical portion 70 or heat sink block 60. At least a portion of each harness passes through a harness clamper attached to a support member, thereby restricting the wiring path.

[0130] In addition, the arrows showing the power path in Figure 43 indicate the flow of current when DC power supplied from the house is converted into DC power of a predetermined voltage by the power conversion device 10, and then supplied to the vehicle, where the on-board battery is charged.

[0131] 44 shows a circuit diagram of a power conversion circuit formed by two power conversion boards 101, 102. The power conversion circuit is a DAB converter, and is configured by connecting a first magnetic component 150, a second magnetic component 151, and a third magnetic component 152 between two full-bridge inverter units 180, 181. The switching of switching elements S1, S2 such as MOS-FETs that constitute each inverter unit 180, 181 is controlled by a control circuit provided in control circuit board 23. This makes it possible to both step up or step down the DC voltage supplied from the house and supply it to on-board battery 3 on the vehicle, and step down or step up the DC voltage supplied from on-board battery 3 and supply it to the house.

[0132] 44, the coupling rate of the second magnetic component 151, which is a transformer, is set high, and the first and third magnetic components form leakage inductance L. On the other hand, only one second magnetic component 151 with a low coupling rate may be connected between the two inverter units 180, 181.

[0133] In Fig. 43, the two power conversion boards 101, 102 and the magnetic components 150, 151, 152 are shown as being separated from each other, but in reality, the power conversion boards 101, 102 and the magnetic components 150, 151, 152 are connected to form the power conversion circuit shown in Fig. 44. Furthermore, switching noise occurs in each of the power conversion boards 101, 102, but this noise is removed by the filter circuits of the filter boards on the power input and output sides. Furthermore, a lot of noise is carried in the current flowing near the terminals of the filter circuit on the power conversion circuit side, but this noise is removed on the house side and vehicle side of each filter board 17, 18.

[0134] 45 , the filter substrates 17, 18 and the power supply circuit board 19 are arranged on the outside of the metal cylindrical portion 70, and the signal lines 97, 98 are arranged on the inside of the cylindrical portion 70. This makes it possible to prevent noise from the filter substrates 17, 18 and the power supply circuit board 19 from being carried on the signal lines 97, 98.

[0135] As a result, even though the signal lines 97, 98 and the power lines are likely to be arranged close to each other in a narrow space in the power conversion device 10, it is possible to improve EMC performance while suppressing increases in costs without using expensive power lines that use ferrite cores.

[0136] Furthermore, in this example, a heat sink block 60 is fixed to the upper side of the cylindrical portion 70, which is on one side of the internal space 138 in the longitudinal direction of the main body panel 80. The intake duct 62 of the heat sink block 60 enters the opening on the upper side of the internal space 138, and the opening is covered by the heat sink block 60. As a result, when the intake duct 62 is made of metal, since the cylindrical main body portion 61 of the heat sink block 60 is made of metal, it is possible to prevent external noise from entering the internal space 138 of the cylindrical portion 70 through the intake port 24b of the housing 24. This allows for further improvement in EMC performance.

[0137] Furthermore, two filter substrates 17, 18 are separately arranged on the left and right outer surfaces of the cylindrical portion 70. As a result, as shown in Fig. 1B, noise from the vicinity of the terminals of first filter substrate 17 on the power conversion circuit side, where a lot of noise is present, and from the common mode coil of first filter substrate 17 is shielded by cylindrical portion 70, thereby suppressing noise from being carried on the current flowing near the home-side and vehicle-side terminals of second filter substrate 18 on the power output side. Note that either electronic components or patterns may be arranged on each filter substrate 17, 18.

[0138] Fig. 46(a) is a schematic diagram corresponding to Fig. 45, showing a state in which adjacent electronic boards are connected by a harness 170. As shown in Fig. 46(a), two filter boards 17, 18 and a power supply circuit board 19 arranged on the outside of the cylindrical portion 70 are connected to each of the filter boards 17, 18 by a harness 170 guided from the power supply circuit board 19 to the outside of the third support member 73 through a harness clamper 163, as indicated by thick solid lines.

[0139] On the other hand, as shown by the dashed line harness 170 in Figure 46(a), a harness clamper (not shown) may be attached near the outer peripheral edge of the main plate portion 73a of the third support member 73 so as to penetrate in the thickness direction, and the harness 170 guided to the opposite side of the third support member 73 through the harness clamper may be connected to each filter substrate 17, 18.

[0140] Furthermore, as shown by the dashed dotted line board-to-board connector 171 in Figure 43, adjacent boards in the circumferential direction of the cylindrical portion 70 or heat sink block 60, or adjacent boards in the longitudinal direction of the cylindrical portion 70 or heat sink block 60, may be electrically connected to each other by the board-to-board connector 171.

[0141] 46(b), for example, a configuration may be adopted in which the width of the power supply circuit board 19 supported by the third support member 73 is made larger than the width of the third support member 73, and one connector of the board-to-board connector 171 protrudes from the surface of the power supply circuit board 19 facing the filter substrates 17 and 18, and the other connector of the board-to-board connector 171 protrudes from the front end of the filter substrates 17 and 18. Then, with the main body panel 80 laid on the top surface of a fixed table such as a desk, the two second support members 71 and 72 protrude in parallel from the top surface of the main body panel 80, and in this state, the third support member 73 is brought close to the front sides of the second support members 71 and 72, so that the one connector and the other connector of the board-to-board connector 171 can be connected.

[0142] In this example, as shown in FIG. 43 , the cylindrical portion 70 and the heat sink block 60 are adjacent to each other in the longitudinal direction of the cylindrical portion 70. Adjacent electronic boards in the circumferential or longitudinal direction of the cylindrical portion 70 are connected to each other by harnesses 170 or board-to-board connectors 171. This simplifies the electrical connection paths of the multiple boards, and eliminates the need to directly connect adjacent boards in a direction inclined relative to the longitudinal direction of the cylindrical portion 70. This prevents multiple wiring paths from approaching and intersecting each other, thereby suppressing noise from being transmitted between the wiring paths.

[0143] In the configuration shown in FIG. 45, the control circuit board 23 may be arranged instead of the power supply circuit board 19 on the third support member 73 arranged on the outside of the cylindrical portion 70.

[0144] FIG. 47 is a diagram corresponding to FIG. 45 and shows three other examples of the arrangement of components arranged inside and outside the cylindrical portion 70. In a first example of the other examples shown in FIG. 47( a), the signal lines 97, 98 are arranged outside the right-side second support member 72, and the second filter substrate 18 is arranged on the inner space 138 side of the right-side second support member 72. Even in this case, noise from the filter substrates 17, 18 can be prevented from being transmitted to the signal lines 97, 98. In this case, even if the power supply circuit board 19 and the control circuit board 23 are supported by the third support member 73 so as to be arranged outside the cylindrical portion 70, the widthwise ends of the third support member 73 protrude beyond the portion that forms the cylindrical portion 70 toward the space in which the signal lines 97, 98 are arranged, thereby preventing noise from being transmitted to the signal lines 97, 98 from the circuit board side.

[0145] In a second example of the modification shown in FIG. 47( b), in the third support member 73, the signal lines 97, 98 are guided and supported by filter clamps or the like so that they are disposed outside the cylindrical portion 70, and the power supply circuit board 19 or the control circuit board 23 is disposed inside the cylindrical portion 70. In this case, noise from the circuit board disposed inside the cylindrical portion 70 can be prevented from being transmitted to the signal lines 97, 98 outside the cylindrical portion 70. Furthermore, both widthwise ends of the third support member 73 protrude beyond the portion forming the cylindrical portion 70 toward the filter substrates 17, 18 so as to separate the space in which the signal lines 97, 98 are disposed from the space in which the filter substrates 17, 18 are disposed. This prevents noise from the filter substrates 17, 18 from being transmitted to the signal lines 97, 98.

[0146] In a third example shown in FIG. 47(c), the signal lines 97 and 98 are arranged separately on the outside of the second support members 71 and 72. The first filter substrate 17 is arranged on the inner space 138 side of the left-side second support member 71, and the second filter substrate 18 is arranged on the inner space 138 side of the right-side second support member 72. A metal plate 182 is fixed to the third support member 73 so as to protrude toward the inner space 138, separating the spaces where the two filter substrates 17 and 18 are arranged. The tip of the metal plate 182 faces or contacts the side surface of the main panel via a gap. This prevents noise from the filter substrates 17 and 18 from being carried by the signal lines 97 and 98.

[0147] FIG. 48 is a block diagram showing a power supply system 300a including a power conversion device 10b according to another example of the embodiment. In the power supply system 300a of this example, the power conversion device 10b is connected between a distribution board 8 or a power switching board and the inverter 7b side of the power station 7. As a result, AC power is supplied from the power station 7, which serves as an external device on the home side, to the power conversion device 10b. For this reason, the power conversion device 10b of this example is provided with an inverter 29 that converts AC power into DC power on the side connected to the power station 7. The inverter 29 is provided inside the first housing, and a terminal of the home side power transmission cable 12 is connected to an input side terminal of the inverter 29 inside a terminal box 50 inside the second housing 40. The board on which the inverter 29 is provided may be supported on the outside of the cylindrical portion 70 by, for example, a third support member 73.

[0148] AC power supplied from the house to the power conversion device 10b is converted to DC power by the inverter 29, then shaped by the first filter substrate 17, and then converted to DC power of a predetermined voltage by the power conversion circuit 21. The converted DC power is shaped by the second filter substrate 18, then supplied to the vehicle, and the in-vehicle battery 3 is charged.

[0149] On the other hand, when power charged in the on-board battery 3 is supplied to the house side via the power conversion device 10b, the DC power supplied from the electric vehicle 2 side to the power conversion device 10 is shaped by the second filter substrate 18 and then converted into DC power that is stepped down or stepped up to a predetermined voltage by the power conversion circuit 21. The converted DC power is shaped by the first filter substrate 17 and then converted into AC power by the inverter 29 and supplied to the house 1 side via the house side power transmission cable 12.

[0150] The present disclosure is further illustrated by the following embodiments. Configuration 1: Main body parts that constitute the housing; two intermediate support members fixed to the inner surface of the main body part so as to protrude toward the same side; a tip support member fixed to the tips of the two intermediate support members, an intermediate electronic board is supported on at least one of the two intermediate support members; The tip support member supports the tip side electronic board, The intermediate support member, the tip support member, and the main body part form a cylindrical portion made of metal. Stationary power conversion equipment. Configuration 2: An electric wire passes through the inner space of the cylindrical portion. 2. The installed power conversion device according to claim 1. Configuration 3: The electric wire is clamped to at least one of the intermediate support member and the tip support member. 3. The installed power conversion device according to claim 2. Configuration 4: The electric wire is a signal line for communication connected to a control board. 4. The installed power conversion device according to configuration 2 or 3. Configuration 5: A heat sink block including a cylindrical portion having a heat dissipation portion on the inside is fixed to one side of the inner space of the cylindrical portion in the longitudinal direction of the main body component, An air intake duct made of metal of the heat sink block is inserted into an opening on one side of the inner space and covers the opening. 5. The installed power conversion device according to any one of configurations 1 to 4. Configuration 6: In the main body component, a heat sink block including a cylindrical portion having a heat dissipation portion on the inside is fixed at a position adjacent to the cylindrical portion in the longitudinal direction, The plurality of electronic boards supported on the plurality of surfaces of the heat sink block, the intermediate side electronic board, and the tip side electronic board are connected by harnesses or board-to-board connectors between the electronic boards adjacent to each other in the circumferential direction or longitudinal direction of the cylindrical portion. 5. The installed power conversion device according to any one of configurations 1 to 4. [Explanation of symbols]

[0151] 1 House, 2 Electric vehicle, 3 Vehicle battery, 4 Power conversion circuit, 5 Storage battery, 6 Solar cell module, 7 Power station, 8 Distribution board, 10, 10a, 10b Installed power conversion device (power conversion device), 12 House side power transmission cable, 14 Vehicle side power transmission cable, 15 Vehicle side connector, 16 Power conversion circuit, 17 First filter board, 18 Second filter board, 19 Power supply circuit board, 20 Power conversion unit, 21 Power conversion circuit, 23 Control circuit board, 24 Housing, 25 Front, 26 Display unit, 29 Inverter, 30 First housing part, 31 Circuit component accommodating space, 32 First housing main body, 40 Second housing part, 41 Installation space, 42 Second housing main body, 50 Terminal box, 51 Terminal box main body, 58 Terminal box cover, 60 Heat sink block, 70 Cylindrical part, 71, 72 Second support member, 73 Third support member, 74 Fourth support member, 80 Main body panel, 92 Ground wire, 93, 97, 98 Signal wire, 101, 102 Power conversion board, 120 Clamp assembly, 150 First magnetic component, 151 Second magnetic component, 152 Third magnetic component, 160, 161, 163 Harness clamper, 170 Harness, 171 Board-to-board connector, 300, 300a Power supply system, A1 First assembly, A2a, A2b Second assembly, A3 Third assembly, A4 Fourth assembly.

Claims

1. a main body part constituting a housing; two intermediate support members fixed to the inner surface of the main body part so as to protrude toward the same side; a tip support member fixed to the tips of the two intermediate support members, an intermediate electronic board is supported on at least one of the two intermediate support members; The tip support member supports the tip side electronic board, The intermediate support member, the tip support member, and the main body part form a cylindrical portion made of metal. Stationary power conversion equipment.

2. An electric wire passes through the inner space of the cylindrical portion. The stationary power conversion device according to claim 1 .

3. The electric wire is clamped to at least one of the intermediate support member and the tip support member. The stationary power conversion device according to claim 2 .

4. The electric wire is a signal line for communication connected to a control board. The stationary power conversion device according to claim 2 .

5. a heat sink block including a cylindrical portion having a heat dissipation portion therein is fixed to one side of the inner space of the cylindrical portion in the longitudinal direction of the main body component; An air intake duct made of metal of the heat sink block is inserted into an opening on one side of the inner space and covers the opening. The stationary power conversion device according to claim 1 .

6. a heat sink block including a cylindrical portion having a heat dissipation portion therein is fixed to the main body component at a position adjacent to the cylindrical portion in the longitudinal direction; The plurality of electronic boards supported on the plurality of surfaces of the heat sink block, the intermediate side electronic board, and the tip side electronic board are connected by harnesses or board-to-board connectors between the electronic boards adjacent to each other in the circumferential direction or longitudinal direction of the cylindrical portion. The stationary power conversion device according to claim 1 .

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