JP7120831B2 - power control unit - Google Patents

Description

The present invention relates to a power control unit for a vehicle using a motor as a propulsion source.

An electric vehicle that uses a motor as a propulsion source is equipped with a charger that converts AC power from a commercial power source into DC power for charging a high-voltage battery.

In a charger mounted on an electric vehicle, a switching circuit for power conversion and a filter circuit for countermeasures against switching noise generated by the switching circuit can be arranged in separate spaces separated by walls. , has been proposed in the past.

According to this proposal, it is possible to suppress noise interference between the switching circuit and the filter circuit (for example, Patent Document 1).

WO2017/022478

In the above-mentioned past proposals, countermeasures against noise interference in chargers for electric vehicles have been considered. On the other hand, with regard to electric vehicles, progress is being made in miniaturizing and increasing the density of on-board components by realizing a power control unit that integrates a charger with other power supply system elements. As a countermeasure against noise interference in such a power control unit, there is room for improvement in the configurations of the past proposals described above.

The present invention has been made in view of the above circumstances, and an object of the present invention is to suppress noise interference in a power control unit that integrates power supply system elements including a charger for a vehicle that includes a motor as a propulsion source. To provide a control unit.

In order to achieve the above object, a power control unit according to one aspect of the present invention comprises:
a charger having a switching circuit that converts input power into battery charging power, and a filter circuit that filters switching noise of the switching circuit on the input side of the switching circuit;
a power module that converts the power of the battery into power for supply to a load;
a separation wall that physically and magnetically separates a first space in which the switching circuit is arranged and a second space in which the filter circuit and the power module are arranged;
Prepare.

Advantageous Effects of Invention According to the present invention, it is possible to suppress noise interference in a power control unit that integrates power system elements including a charger of a vehicle that includes a motor as a propulsion source.

1 is a perspective view showing a partially exploded power control unit of an electric vehicle according to an embodiment of the present invention; FIG. FIG. 2 is a sectional view taken along the line II of FIG. 1; FIG. 3 is a sectional view taken along line II-II of FIG. 2;

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a perspective view showing a partially exploded power control unit of an electric vehicle according to one embodiment of the present invention. The power control unit of this embodiment shown in FIG. 1 is mounted on an electric vehicle including a motor as a propulsion source. In this embodiment, a power control unit installed in a plug-in hybrid vehicle (PHEV) will be described.

The power control unit 1 of the present embodiment shown in FIG. 1 charges and discharges a high-voltage battery (not shown) that serves as a power source for a propulsion motor (not shown) of an electric vehicle, and a low-voltage load (not shown) of an electric vehicle. Auxiliary equipment) is provided by consolidating elements related to charging of a low-voltage battery (not shown) that serves as a power source.

The power control unit 1 has a lower case 3 and an upper case 5 laid thereon. The lower case 3 and the upper case 5 are formed by casting a metal material such as aluminum that has a magnetic shielding function and high thermal conductivity.

FIG. 2 is a sectional view taken along line II of FIG. As shown in FIG. 2, the lower case 3 has a housing portion 7 that opens to the bottom. The opening of the housing portion 7 is closed by the lid 9 . A wiring hole 11 communicating with the accommodating portion 7 is formed in a ceiling surface 12 (corresponding to a partition wall in claims) of the lower case 3 .

Further, the ceiling surface 12 of the lower case 3 is provided with a flow path 17 through which the cooling water 15 of the water jacket 13 flows. The flow path 17 communicates with water inlet/outlet ports 19 and 21 formed on one side surface of the lower case 3 shown in FIG.

As shown in FIG. 2, the upper case 5 has a housing portion 23 opening at the bottom. The opening of the accommodating portion 23 is closed by the ceiling surface 12 of the lower case 3 on which the upper case 5 is placed. Work openings 25 and 27 are formed in the ceiling surface 24 of the upper case 5 to expose the parts and the like stored in the storage portion 23 . The working openings 25 and 27 are closed by lids 29 and 31 .

One of the side surfaces of the upper case 5 is formed with port mounting holes 33 and 35 as shown in FIG. A quick charge port QP is attached to the port attachment hole 33 . A high voltage battery port HBP is attached to the port attachment hole 35 .

FIG. 3 is a cross-sectional view taken along line II--II of FIG. As shown in FIG. 3, the power control unit 1 has a plug-in charger CHG, a smoothing module SM, a power module PM, a DCDC converter 37 and a busbar module BM.

A plug-in charger (ordinary charger) CHG (corresponding to the charger in claims) has an ACDC converter 39 and an AC (alternating current) filter 41 .

The ACDC converter 39 (corresponding to the switching circuit in the claims) converts the AC power of a commercial power source (for example, single-phase AC 200V) input from the commercial power port CP (corresponding to the input connector in the claims) to DC power with a voltage corresponding to the high voltage battery. The commercial power port CP is provided on the side surface 42 of the lower case 3 (corresponding to the side wall on which the input connector is arranged).

The ACDC converter 39 is housed in the housing portion 23 (corresponding to the first space in the claims) of the upper case 5, as shown in FIG.

An AC filter 41 (corresponding to a filter circuit in claims) shown in FIG. 3 is connected to the ACDC converter 39 and the commercial power supply port CP. The AC filter 41 suppresses switching noise generated by switching of the ACDC converter 39 during charging of the high-voltage battery (not shown) from propagating from the commercial power supply port CP to the commercial power supply side.

The AC filter 41 is housed in the housing portion 7 (corresponding to the second space in the claims) of the lower case 3, as shown in FIG. The AC filter 41 of the accommodating portion 7 is arranged close to the side surface 42 of the lower case 3 on which the commercial power supply port CP is provided. ACDC converter 39 of upper case 5 and AC filter 41 of lower case 3 are connected by cable 43 passed through wiring hole 11 of lower case 3 .

The smoothing module SM shown in FIG. 3 has a smoothing capacitor, a main relay, and a controller mounted on a common circuit board (not shown). The smoothing module SM is housed in the housing portion 7 of the lower case 3, as shown in FIG.

The smoothing capacitor smoothes the current when the power module PM drives an inverter, which will be described later, and a DCDC converter 37, which will be described later. Further, the smoothing capacitor smoothes the current when the ACDC converter 39 of the plug-in charger CHG converts AC power from the commercial power supply into DC power.

The main relay outputs DC power input from a high-voltage battery (not shown) to the high-voltage battery port HBP to the smoothing capacitor of the smoothing module SM when the inverter of the power module PM converts DC power into three-phase AC power. (turns on the connection).

Alternatively, this main relay converts the DC power input to the high-voltage battery port HBP into a low voltage and outputs it from the low-voltage battery port LBP to a low-voltage battery (not shown) by a DCDC converter 37, which will be described later. Allows output to the DCDC converter 37 .

In addition, this main relay allows charging of the high voltage battery during fast charging and normal charging.

When the electric vehicle is in a state other than these states, the main relay is normally in an OFF state.

A controller (corresponding to a control circuit in the claims) controls the operation of the main relay, and also functions as a driver circuit for the DCDC converter 37 and the ACDC converter 39 of the plug-in charger CHG, and an inverter driver circuit for the power module PM, which will be described later. and other operations.

The power module PM shown in FIG. 3 has inverters and driver circuits mounted on a common circuit board (not shown). The power module PM is housed in the housing portion 7 of the lower case 3, as shown in FIG. The power module PM is arranged between the AC filter 41 of the accommodation section 7 and the smoothing module SM.

The inverter converts DC power (for example, DC 400V) of the high voltage battery input from the high voltage battery port HBP into three-phase AC power and outputs it to a propulsion motor (not shown). This inverter has power semiconductor switching elements in the upper arm and the lower arm of each phase of UVW.

This inverter does not operate when charging the high voltage battery (not shown). Therefore, even if the power module PM is arranged adjacent to the AC filter 41 that removes the switching noise of the ACDC converter 39 generated during charging of the high voltage battery, it does not adversely affect the operation of the inverter.

In this embodiment, the configuration in which the inverter converts to three-phase alternating current power is taken as an example, but the configuration may be such that the inverter converts to three-phase or more multi-phase alternating current (the configuration of the inverter in that case is omitted). ).

Each power semiconductor switching element can be composed of, for example, an IGBT (Insulated Gate Bipolar Transistor). Also, each power semiconductor switching element can be configured by a power MOSFET.

The drive circuit is composed of a gate drive circuit when each power semiconductor switching element is an IGBT or a power MOSFET.

The DCDC converter 37 voltage-converts the DC power of the high-voltage battery input from the high-voltage battery port HBP into low-voltage DC power, and outputs the low-voltage DC power to the low-voltage battery port LBP. For the DCDC converter 37, for example, an asymmetrical half-bridge LLC converter having an LLC circuit on the primary side can be used. The DCDC converter 37 is housed in the housing portion 7 of the lower case 3, as shown in FIG.

Low-voltage battery port LBP is provided on side surface 44 adjacent to side surface 42 of lower case 3 on which commercial power supply port CP is provided. As shown in FIG. 3, the DCDC converter 37 of the housing portion 7 is arranged close to the side surface 44 provided with the low-voltage battery port LBP, and is disposed adjacent to the side surface 42 provided with the commercial power supply port CP with the AC filter 41 interposed therebetween. is placed on the opposite side.

A smoothing module SM including a controller for controlling the operation of the driver circuit of the DCDC converter 37 is arranged in the housing portion 7 of the lower case 3 at a location further away from the AC filter 41 than the DCDC converter 37 as shown in FIG. there is

The busbar module BM includes a busbar (not shown) that connects the ACDC converter 39 of the plug-in charger CHG to the quick charge port QP and the high voltage battery port HBP, and the ACDC converter 39 to the quick charge port when the quick charge port QP is open. It has a QC relay (not shown) that cuts off the QP.

In the power control unit 1 of this embodiment configured as described above, when the upper case 5 is placed on top of the lower case 3 , the entire AC filter 41 accommodated in the accommodation portion 7 of the lower case 3 is placed in the accommodation portion of the upper case 5 . The ACDC converter 39 housed in 23 overlaps the lower case 3 and the upper case 5 in the stacking direction.

Therefore, the length of the cable 43 connecting the ACDC converter 39 and the AC filter 41 and the wiring hole 11 passing therethrough can be minimized. As a result, the signal of the cable 43 is less likely to be affected by noise due to the switching of the ACDC converter 39 .

In addition, in the power control unit 1 of the present embodiment, the smoothing module SM is arranged in the accommodation portion 7 of the lower case 3 at a location further away from the AC filter 41 than the DCDC converter 37 is.

Therefore, the effect of the switching noise of the ACDC converter 39 removed by the AC filter 41 on the operation control of the DCDC converter 37 by the controller of the smoothing module SM can be minimized.

In addition, a side surface 42 different from the side surface 44 of the lower case 3 provided with a commercial power supply port CP that suppresses the propagation of switching noise of the ACDC converter 39 to the commercial power supply side with an AC filter 41 is provided with a low power supply transformer transformed by the DCDC converter 37 . A low voltage battery port LBP is provided to output a DC voltage for a voltage battery.

Therefore, the effect of the switching noise of the ACDC converter 39 removed by the AC filter 41 on the low-voltage DC voltage for the low-voltage battery transformed by the DCDC converter 37 can be minimized.

INDUSTRIAL APPLICABILITY The present invention can be used in a power control unit of a vehicle using a motor as a propulsion source.

1 Power Control Unit 3 Lower Case 5 Upper Case 7 Housing (Second Space)
9 Lid 11 Wiring hole 12 Lower case ceiling surface (separation wall)
13 Water jacket 15 Cooling water (cooling liquid)
17 Flow path 19 Water inlet port 21 Water outlet port 23 Storage part (first space)
24 Ceiling surface of upper case 25, 27 Working opening 29, 31 Lid 33, 35 Port mounting hole 37 DCDC converter 39 ACDC converter (switching circuit)
41 AC filter (filter circuit)
42 Lower case side (side wall where input connector is arranged)
43 Cable 44 Lower case side BM Busbar module CHG Plug-in charger (charger)
CP Commercial power port HBP High voltage battery port LBP Low voltage battery port PM Power module QP Quick charge port SM Smoothing module (control circuit)

Claims (4)

A switching circuit (39) for converting input power into battery charging power, and a filter circuit (41) for filtering switching noise of the switching circuit (39) on the input side of the switching circuit (39). a charger (CHG);
a power module (PM) that converts the power of the battery into power for supply to a load;
Isolation that physically and magnetically separates a first space (23) in which the switching circuit (39) is arranged and a second space (7) in which the filter circuit (41) and the power module (PM) are arranged. a wall (12);
a DCDC converter (37) that transforms the charging power;
A control circuit (SM) for controlling the operation of the DCDC converter (37),
The DCDC converter (37) and the control circuit (SM) are arranged in the second space (7), and the control circuit (SM) is arranged in the filter circuit (41) rather than the DCDC converter (37). is located at a distance from
A power control unit (1). At least a part of the filter circuit (41) is located at a position overlapping the switching circuit (39), the first space (23) and the second space (7) in the stacking direction with the isolation wall (12) interposed therebetween. A power control unit (1) according to claim 1, arranged. 3. The isolation wall (12) has therein a channel (17) through which a cooling liquid (15) for cooling the first space (23) and the second space (7) flows. A power control unit (1) as described. An input connector (CP) for power input to the charger (CHG) is connected to the DCDC connector on the side wall of the housing (3) having the second space (7) inside, with the filter circuit (41) interposed therebetween. 2. Power control unit (1) according to claim 1 , arranged on a side wall (42) located opposite to the converter (37) side .

Images