JP7540177B2 - Power Conversion Equipment - Google Patents

Description

This invention relates to a power conversion device, and in particular to a power conversion device that has a main circuit section for converting electric power.

Conventionally, a power conversion device having a main circuit section for converting electric power is known (see, for example, Patent Document 1).

The power conversion device of the above-mentioned Patent Document 1 includes a power conversion unit that converts power by switching operation of a semiconductor element, a switch, a reactor, a smoothing circuit, a blower, and a housing that is unitized into a plurality of units from a first unit to a fourth unit. The electronic components such as the semiconductor elements that constitute the power conversion unit are housed in a first unit in which the inside of the housing is divided by a partition into a sealed section into which outside air does not flow and an open section into which outside air flows. The blower is housed in a second unit into which outside air flows, and the reactor is housed in a third unit into which outside air flows. Furthermore, the switch and the smoothing circuit are housed in a fourth unit into which outside air does not flow. In addition, the first unit and the second unit are adjacent to each other on their sides, and are adjacent to each other on their sides in a direction perpendicular to the direction in which the first unit and the second unit are adjacent. The third unit and the fourth unit are adjacent to each other on their sides in the direction in which the first unit and the second unit are adjacent. In addition, the third unit and the second unit are adjacent on their sides in the direction in which the first unit and the fourth unit are adjacent. In the power conversion device of Patent Document 1, the main circuit for power conversion is composed of a switch, a reactor, a power conversion section, and a smoothing circuit, in that order. Therefore, the devices and circuits that make up the main circuit for power conversion are arranged in the order of the fourth unit, the third unit, the first unit, and the fourth unit.

International Publication No. 2018/020615

In the power conversion device of Patent Document 1, the devices and circuits that make up the main circuit for power conversion are arranged in the following order: fourth unit, third unit, first unit, fourth unit. However, the third unit is not adjacent to the side of the first unit. Therefore, in order to electrically connect the reactor housed in the third unit and the power conversion section housed in the first unit, it is considered that the wiring that makes up the main circuit is provided to pass through the fourth unit or the second unit. Therefore, there is a problem in that the weight of the device increases due to the increase in the length of the wiring and the increase in the number of wiring.

This invention has been made to solve the above problems, and one object of the invention is to provide a power conversion device that can suppress the increase in device weight caused by an increase in wiring length and number of wiring.

In order to achieve the above object, a power conversion device according to one aspect of the present invention includes a first main circuit section that converts electric power, a second main circuit section that converts the electric power converted by the first main circuit section, a transformer that converts voltage between the first main circuit section and the second main circuit section, a reactor to which the electric power converted by the second main circuit section is input, and a housing including a first housing section that houses the first main circuit section, a second housing section that houses the second main circuit section, and a third housing section in which the transformer and the reactor are disposed, and wiring and devices that constitute a main circuit for power conversion including the first main circuit section and the second main circuit section are arranged inside the housing, and are connected to an input of the main circuit. The first main circuit section, the transformer, the second main circuit section, and the reactor are arranged in this order so as to follow the order of electrical connection of the main circuit from the input side to the output side, and a part of the wiring constituting the main circuit is provided from the inside to the outside of each of the first and second housing sections that accommodate the first and second main circuit sections, respectively, the second housing section is arranged below the first housing section , the third housing section is arranged below the first housing section and above the second housing section, and the transformer is electrically connected to the first main circuit section by wiring provided in the vertical direction so as to straddle the boundary between the first and third housing sections. As a result , the first and second housing sections overlap in the vertical direction, thereby suppressing an increase in the installation area (bottom area) of the power conversion device. In addition, inside the housing, the wiring and devices constituting the main circuit are arranged in order from the input side to the output side of the main circuit so as to follow the order of electrical connection of the main circuit, thereby shortening the length of the wiring constituting the main circuit. As a result, it is possible to provide a power conversion device capable of suppressing an increase in device weight due to an increase in wiring length and an increase in the number of wirings. In addition, by arranging the wiring and devices in accordance with the order of electrical connections of the main circuit, the arrangement of the wiring and devices is not complicated, and assembly work can be easily performed. In addition, since the first main circuit unit, the transformer, the second main circuit unit, and the reactor can be arranged in accordance with the flow of current in the main circuit, it is possible to shorten the length of wiring connecting each of the first main circuit unit, the transformer, the second main circuit unit, and the reactor. This makes it possible to suppress an increase in device weight due to an increase in the length of wiring connecting each of the first main circuit unit, the transformer, the second main circuit unit, and the reactor.

In the above-mentioned configuration in which the second housing section is disposed below the first housing section , the third housing section is preferably disposed so as to cover the upper and sides of the second housing section, and the transformer and the reactor are disposed so as to sandwich the second housing section therebetween and are electrically connected to the second main circuit section by wiring provided so as to straddle the boundary between the third housing section and the second housing section. With this configuration, the transformer and the reactor, which generate a relatively large amount of heat, can be spaced apart from each other, thereby suppressing a decrease in the heat dissipation efficiency of the transformer and the reactor.

In this case, preferably, the first housing is configured to hermetically house the first main circuit, and the second housing is configured to hermetically house the second main circuit. With this configuration, the first main circuit and the second main circuit can be hermetically housed in the first housing and the second housing, respectively, so that the first main circuit and the second main circuit can be protected from dust and moisture. In addition, the transformer and the reactor are disposed in the third housing, and can be disposed outside the sealed first and second housings, so that they can be effectively cooled by the outside air.

In the above-mentioned configuration in which the first housing is configured to hermetically house the first main circuit section and the second housing is configured to hermetically house the second main circuit section, preferably, a filter section is provided on the input side of the first main circuit section, the filter section is housed in the first housing section and is electrically connected to the first main circuit section by wiring provided inside the first housing section, and inside the housing, the filter section, the first main circuit section, the transformer, the second main circuit section and the reactor are arranged in this order from the input side to the output side of the main circuit. With this configuration, the filter section, the first main circuit section, the transformer, the second main circuit section and the reactor can be arranged along the current flow of the main circuit, so that the wiring length connecting each of the filter section, the first main circuit section, the transformer, the second main circuit section and the reactor can be shortened. This makes it possible to suppress an increase in the weight of the device caused by an increase in the wiring length connecting each of the filter section, the first main circuit section, the transformer, the second main circuit section and the reactor.

In this case, preferably, the filter unit further includes an input connector unit that is electrically connected to an external wiring and inputs power from the external wiring to the filter unit, and the input connector unit is provided on the side of the housing closer to the filter unit. With this configuration, the length of the wiring connecting the input connector unit and the filter unit can be shortened. This makes it possible to suppress an increase in the weight of the device caused by an increase in the length of the wiring connecting the input connector unit and the filter unit.

In the power conversion device according to the above aspect, preferably, the device further includes an output connector unit that is electrically connected to external wiring and outputs the power converted by the main circuit to the external wiring, and the output connector unit is provided on the side of the housing closer to the reactor. With this configuration, the length of the wiring connecting the output connector unit and the reactor can be shortened. This makes it possible to suppress an increase in the weight of the device caused by an increase in the length of the wiring connecting the output connector unit and the reactor.

In the power conversion device according to the above aspect, preferably, the first main circuit section includes a semiconductor switching element that converts DC power to AC power, and further includes a control section that controls the semiconductor switching element, and the control section is housed in the first housing section together with the first main circuit section, and the second main circuit section includes a diode that rectifies AC power to DC power and is housed in a second housing section different from the first housing section in which the control section is housed. With this configuration, the control section is housed in the first housing section together with the first main circuit section including the semiconductor switching element, and compared to the case in which the control section is housed in a section other than the first housing section, the wiring length connecting the semiconductor switching element and the control section can be shortened. This makes it possible to suppress an increase in the weight of the device due to an increase in the wiring length connecting the semiconductor switching element and the control section. In addition, since the diode is not controlled by the control section, there is no need to provide wiring connecting the diode and the control section, and even if the diode is housed in the second housing section in which the control section is not housed, there is no increase in the wiring length and the number of wirings. This makes it possible to further suppress an increase in the weight of the device due to an increase in the wiring length and the number of wirings.

In the power conversion device according to the above aspect, preferably, the power conversion device further includes a first cooling section including a first heat dissipation fin and on which the first main circuit section is placed, a second cooling section including a second heat dissipation fin and on which the second main circuit section is placed, and an air blowing section for blowing cooling air to the first heat dissipation fin and the second heat dissipation fin, the first heat dissipation fin being arranged in the third housing section, the second heat dissipation fin being arranged in the third housing section so as to face the first heat dissipation fin and be spaced a predetermined distance from the first heat dissipation fin, and the air blowing section is arranged on the side of the third housing section where the reactor is arranged, and an exhaust port for discharging the cooling air is arranged on the side where the transformer is arranged. With this configuration, the first heat dissipation fin and the second heat dissipation fin can be cooled by the cooling air blown by the air blowing section and ventilating the inside of the third housing section, thereby cooling the first main circuit section and the second main circuit section, and therefore the first main circuit section and the second main circuit section can be efficiently cooled. In addition, by placing the air blowing section on the side where the reactor is located, and the exhaust port for discharging the cooling air on the side where the transformer is located, the reactor, which generates more heat than the transformer, is placed upstream of the cooling air, allowing the reactor to be cooled efficiently.

As described above, the present invention provides a power conversion device that can suppress the increase in device weight caused by an increase in wiring length and number of wiring.

1 is an example of a circuit diagram of a power conversion device according to a first embodiment; 1 is a perspective view of a power conversion device according to a first embodiment; 2 is a side view showing the arrangement of wiring and devices within a housing of the power conversion device of the first embodiment. FIG. 2 is a cross-sectional view taken along line 200-200 in FIG. FIG. 2 is a top view of the power conversion device according to the first embodiment. FIG. 2 is a bottom view of the power conversion device according to the first embodiment. FIG. 4 is a diagram showing a flow of a main circuit according to the first embodiment. 13 is a side view showing the arrangement of wiring and devices within a housing of a power conversion device according to a second embodiment. FIG. FIG. 11 is a side view of a power conversion device according to a modified example.

The following describes an embodiment of the present invention with reference to the drawings.

[First embodiment]
A configuration of a power conversion device 100 according to a first embodiment will be described with reference to Figures 1 to 6. In the first embodiment, the power conversion device 100 is disposed in a railway vehicle 1 (see Figure 4). For example, the power conversion device 100 is disposed in a space 1a below a passenger compartment of the railway vehicle 1. In this specification, the Z direction is the vertical direction, the Z1 direction is the upward direction, and the Z2 direction is the downward direction. The X direction and the Y direction are directions perpendicular to each other along a horizontal plane.

First, the circuit configuration of the power conversion device 100 will be described with reference to FIG.

The power conversion device 100 includes a first main circuit section 10 (inverter) that converts DC power output from an external DC power source into AC power. The first main circuit section 10 includes a plurality of semiconductor switching elements 10a that convert DC power into AC power.

The power conversion device 100 also includes a filter section 12 provided on the input side of the first main circuit section 10. The filter section 12 is, for example, a filter circuit configured with an inductor 12a and a capacitor 12b for extracting a specific (target) frequency component.

The power conversion device 100 also includes a transformer 20. The transformer 20 is configured to convert voltage between the first main circuit section 10 and a second main circuit section 11, which will be described later.

The power conversion device 100 also includes a second main circuit section 11 (rectifier section). The second main circuit section 11 is configured to rectify (convert into DC) the AC power from the first main circuit section 10. That is, the second main circuit section 11 is configured to convert the power converted by the first main circuit section 10. The second main circuit section 11 includes a plurality of diodes 11a that rectify AC power into DC power. The second main circuit section 11 is also connected to a reactor 21 that smoothes the DC power converted by the plurality of diodes 11a. The reactor 21 is configured to receive the power converted by the second main circuit section 11, and the DC power smoothed by the reactor 21 is supplied to a load outside the device. A smoothing circuit is formed by a capacitor outside the device, for example, a capacitor provided in another power conversion device connected to the power conversion device 100, and the reactor 21.

(Structure of power conversion device 100)
Next, the housing H of the power conversion device 100 and the configuration inside the housing H will be described with reference to Figures 2 to 6. Note that in Figures 5 and 6, in order to illustrate the inside of the power conversion device 100, the power conversion device 100 is depicted as if it is open above and below. However, in reality, the power conversion device 100 is closed above and below.

As shown in FIG. 2, the housing H of the power conversion device 100 includes an upper housing section 30 and an intermediate housing section 40. The intermediate housing section 40 is disposed below the upper housing section 30. The upper housing section 30 is an example of a "first housing section" in the claims, and the intermediate housing section 40 is an example of a "third housing section" in the claims.

In the first embodiment, the power conversion device 100 includes a blower unit 60. The power conversion device 100 also includes an input connector unit 71 and an output connector unit 72. Two output connector units 72 are provided, one for each of the P phase and the N phase.

As shown in Figures 3 and 4, the housing H of the power conversion device 100 includes a lower housing section 50 in addition to an upper housing section 30 and an intermediate housing section 40. The lower housing section 50 is an example of the "second housing section" in the claims.

In the first embodiment, the upper housing unit 30 and the lower housing unit 50 are arranged so as to overlap in the vertical direction. The lower housing unit 50 is arranged below the upper housing unit 30. The intermediate housing unit 40 is arranged so as to cover the upper and sides of the lower housing unit 50.

Specifically, a convex lower housing part 50 is provided on the surface 40a on the Z2 direction side of the intermediate housing part 40. In addition, a recess 31 of the upper housing part 30 that is recessed in the Z1 direction is disposed on the Z1 direction side (above) of the convex lower housing part 50.

As shown in Figures 3 and 4, the power conversion device 100 includes an upper cooling section 80 on which the first main circuit section 10 is placed. The upper cooling section 80 includes an upper cooling body section 81 on which the first main circuit section 10 is placed, and upper heat dissipation fins 82 provided on the upper cooling body section 81. The upper heat dissipation fins 82 are provided so as to protrude in the Z2 direction from the Z2 direction side surface of the upper cooling body section 81. A plurality of upper heat dissipation fins 82 are provided. The upper cooling section 80 and the upper heat dissipation fins 82 are examples of the "first cooling section" and "first heat dissipation fins" in the claims, respectively.

The upper cooling section 80 is disposed on the bottom surface 31a of the recess 31. The recess 31 has an opening 31b (see FIG. 5). The opening 31b is closed by the upper cooling main body section 81. A part of the upper cooling main body section 81 and a plurality of semiconductor switching elements 10a (a part of the first main circuit section 10) are exposed from the opening 31b.

As shown in Figures 3 and 4, the upper housing part 30 is configured to house the first main circuit part 10 placed on the upper cooling part 80. The upper housing part 30 is provided with a recess 31 recessed upward (Z1 direction). The recess 31 is provided on the Z2 direction side of the upper housing part 30. The upper housing part 30 is made of sheet metal, for example. The recess 31 is fixed to the surface 30a on the Z2 direction side of the upper housing part 30 by screws or the like.

In the first embodiment, as shown in FIG. 3 and FIG. 4, the upper housing part 30 is configured to accommodate the first main circuit part 10. Specifically, the interior of the upper housing part 30 with the opening 31b blocked by the upper cooling body part 81 is a sealed space SP1. The first main circuit part 10 is arranged inside the upper housing part 30 (sealed space SP1). That is, the upper housing part 30 is configured to accommodate the first main circuit part 10 in a sealed manner. In addition, a plurality of semiconductor switching elements 10a of the first main circuit part 10 are arranged along the Y direction. The first main circuit part 10 is formed on a main circuit board PB1. The main circuit board PB1 is a printed circuit board (PCB) on which a conductor pattern is formed and electronic components are attached. Note that electrical components (not shown) other than the first main circuit part 10 are also arranged inside the upper housing part 30. Additionally, no cooling air flows inside the upper housing section 30 from the blower section 60, which will be described later.

3 and 4, the upper housing 30 houses the filter section 12. The filter section 12 is electrically connected to the first main circuit section 10 by wiring provided inside the upper housing 30. Specifically, the filter section 12 is formed on the filter substrate PB2. The filter substrate PB2 is a printed circuit board (PCB) on which a conductor pattern is formed and electronic components are attached. The filter section 12 is electrically connected to the input connector section 71 via the wiring V1, the connector CN provided on the filter substrate PB2, and the conductor pattern of the filter substrate PB2. The filter section 12 is disposed on the X1 direction side (input connector section 71 side) of the housing H with respect to the first main circuit section 10. The filter section 12 is also electrically connected to the first main circuit section 10 by electrically connecting the conductor pattern of the filter substrate PB2 and the conductor pattern of the main circuit substrate PB1 by the bus bar (copper bar) B1.

The input connector unit 71 is electrically connected to an external wiring (not shown) and is configured to input power from the external wiring to the filter unit 12. As shown in FIG. 3, the input connector unit 71 is provided on the side surface of the housing H that is closer to the filter unit 12. Specifically, the input connector unit 71 is provided on the side surface 30b of the upper housing unit 30 that is closer to the filter unit 12. The side surface 30b of the upper housing unit 30 is an example of the "side surface of the housing that is closer to the filter unit" in the claims.

In the first embodiment, as shown in Figs. 3 and 4, the power conversion device 100 includes a control unit 70 that controls the semiconductor switching element 10a (first main circuit unit 10). The control unit 70 is housed in the upper housing unit 30 together with the first main circuit unit 10. That is, the control unit 70 is sealed by the upper housing unit 30 together with the first main circuit unit 10. The control unit 70 is formed on a control board PB3. The control board PB3 is a printed circuit board (PCB) on which a conductor pattern is formed and on which electronic components are attached.

3 and 4, the power conversion device 100 includes a lower cooling section 90. The lower cooling section 90 includes a lower cooling body section 91 on which the second main circuit section 11 is placed, and a lower heat dissipation fin 92 provided on the lower cooling body section 91. In the first embodiment, the lower heat dissipation fin 92 (lower cooling section 90) faces the upper heat dissipation fin 82 (upper cooling section 80) and is provided so as to be spaced apart at a predetermined distance D when viewed from a direction (X direction and Y direction) perpendicular to the direction facing the upper heat dissipation fin 82 (Z direction). The second main circuit section 11 is placed on the lower cooling section 90. In the Z direction, the lower cooling section 90 faces the upper cooling section 80. The second main circuit section 11 is provided on the Z2 direction side of the lower cooling section 90. The lower heat dissipation fins 92 are provided so as to protrude in the Z1 direction from the surface of the lower cooling body 91 on the Z1 direction side. A plurality of lower heat dissipation fins 92 are provided. The lower cooling section 90 and the lower heat dissipation fins 92 are examples of the "second cooling section" and "second heat dissipation fins" in the claims, respectively.

An opening 50b (see FIG. 6) is provided on the surface 40a on the Z1 direction side of the lower housing part 50. The opening 50b is closed by the lower cooling body part 91. A part of the lower cooling body part 91 and the diode 11a (second main circuit part 11) are exposed from the opening 50b.

As shown in Figs. 3 and 4, the lower housing section 50 is configured to house the second main circuit section 11 placed on the lower cooling section 90. Specifically, the lower housing section 50 is arranged to face the recess 31 of the upper housing section 30 and to protrude from the surface on which the lower housing section 50 is arranged (the surface 40a on the Z2 direction side of the intermediate housing section 40) toward the recess 31. The lower housing section 50 is made of, for example, sheet metal. The lower housing section 50 is fixed to the intermediate housing section 40 by screws or the like.

In the first embodiment, as shown in FIG. 3 and FIG. 4, the lower housing part 50 is configured to accommodate the second main circuit part 11. Specifically, the interior of the lower housing part 50 with the opening 50b blocked by the lower cooling body part 91 is a sealed space SP2. The second main circuit part 11 is arranged inside the lower housing part 50 (sealed space SP2). That is, the lower housing part 50 is configured to hermetically accommodate the second main circuit part 11, and the second main circuit part 11 including the diode 11a is accommodated in the lower housing part 50, which is different from the upper housing part 30 in which the control part 70 is accommodated. Also, as shown in FIG. 4 and FIG. 6, the multiple diodes 11a of the second main circuit part 11 are arranged in the Y direction. Note that electrical components (not shown) other than the second main circuit part 11 are also arranged inside the lower housing part 50. Also, cooling air from the blower part 60 described later does not flow inside the lower housing part 50.

As shown in Figures 3 and 4, the transformer 20 and reactor 21 are arranged in the intermediate housing section 40.

In the first embodiment, a portion of the wiring constituting the main circuit is provided from the inside to the outside (from the outside to the inside) of the upper housing section 30 that houses the first main circuit section 10.

The transformer 20 is electrically connected to the first main circuit section 10 by a wiring V2 provided along the vertical direction so as to straddle the boundary between the upper housing section 30 and the intermediate housing section 40. Specifically, the wiring V2 is electrically connected to a bus bar (copper bar) B2 electrically connected to the conductor pattern of the main circuit board PB1 on which the first main circuit section 10 is formed, on the X2 direction side inside the upper housing section 30. The wiring V2 is provided in a direction from the upper housing section 30 toward the intermediate housing section 40, that is, along the vertical direction (Z direction). The wiring V2 penetrates the surface 30a on the Z2 direction side of the upper housing section 30. The wiring V2 is an insulated wiring in which the conductor is covered with an insulator, and the portion of the surface 30a on the Z2 direction side of the upper housing section 30 through which the wiring V2 penetrates is sealed to seal the upper housing section 30. The wiring V2 is electrically connected to the transformer 20 inside the intermediate housing section 40. As a result, the transformer 20 is electrically connected to the first main circuit section 10 via the wiring V2, the bus bar B2, and the conductor pattern of the main circuit board PB1.

In the first embodiment, the transformer 20 and the reactor 21 are arranged to sandwich the lower housing unit 50 between them. That is, the transformer 20 and the reactor 21 are respectively arranged on one side and the other side of the opposing sides of the lower housing unit 50 inside the intermediate housing unit 40. Specifically, the transformer 20 is arranged on the face 50c side of the lower housing unit 50, i.e., on the X2 direction side of the lower housing unit 50. Furthermore, the reactor 21 is arranged on the face 50d side facing the face 50c of the lower housing unit 50, i.e., on the X1 direction side of the lower housing unit 50.

The transformer 20 and the reactor 21 are electrically connected to the second main circuit section 11 by wiring V3 and wiring V4, respectively, which are arranged to straddle the boundary between the intermediate housing section 40 and the lower housing section 50.

In addition, in the first embodiment, a portion of the wiring constituting the main circuit is provided from the inside to the outside (from the outside to the inside) of the lower housing part 50 that houses the second main circuit part 11.

Specifically, the wiring V3 is electrically connected to the transformer 20 inside the intermediate housing part 40. The wiring V3 is arranged to extend horizontally from the X2 direction side where the transformer 20 of the intermediate housing part 40 is arranged toward the lower housing part 50 (X1 direction). The wiring V3 penetrates the surface 50c on the X2 direction side of the lower housing part 50. The wiring V3 is an insulated wiring, and the portion of the surface 50c of the lower housing part 50 through which the wiring V3 penetrates is sealed to seal the lower housing part 50. The wiring V3 is electrically connected to the bus bar (copper bar) B3 electrically connected to the second main circuit part 11 (diode 11a) inside the lower housing part 50. As a result, the transformer 20 is electrically connected to the second main circuit part 11 (diode 11a) via the wiring V3 and the bus bar B3.

The wiring V4 is electrically connected to the bus bar (copper bar) B4 electrically connected to the second main circuit unit 11 (diode 11a) inside the lower housing unit 50. The wiring V4 is arranged to extend horizontally from inside the lower housing unit 50 toward the X1 direction side where the reactor 21 of the intermediate housing unit 40 is arranged. The wiring V4 penetrates the surface 50d on the X1 direction side of the lower housing unit 50. The wiring V4 is an insulated wiring, and the portion of the surface 50d of the lower housing unit 50 through which the wiring V4 penetrates is sealed to seal the lower housing unit 50. The wiring V4 is electrically connected to the reactor 21 inside the intermediate housing unit 40. As a result, the second main circuit unit 11 (diode 11a) is electrically connected to the reactor 21 via the bus bar B4 and the wiring V4.

The reactor 21 is electrically connected to the output connector 72 by a wiring V5 provided along the vertical direction so as to straddle the boundary between the upper housing part 30 and the intermediate housing part 40. Specifically, the wiring V5 is electrically connected to the reactor 21 inside the intermediate housing part 40. The wiring V5 is provided in a direction from the intermediate housing part 40 toward the upper housing part 30, that is, along the vertical direction (Z direction). The wiring V5 penetrates the surface 30a on the Z2 direction side of the upper housing part 30. The wiring V5 is an insulated wiring, and the portion of the surface 30a on the Z2 direction side of the upper housing part 30 through which the wiring V5 penetrates is sealed to seal the upper housing part 30. The wiring V5 is electrically connected to the bus bar (copper bar) B5 electrically connected to the output connector part 72 inside the upper housing part 30. As a result, the reactor 21 is electrically connected to the output connector part 72 via the wiring V5 and the bus bar B5. As shown in FIG. 6, multiple transformers 20 and reactors 21 are provided. The current from the first main circuit unit 10 is branched to multiple transformers 20 by bus bar B2 electrically connected to multiple wirings V2, and the current from multiple reactors 21 is merged at bus bar B5 electrically connected to multiple wirings V5.

The output connector unit 72 is electrically connected to external wiring (not shown) and is configured to output the power converted by the main circuit to the external wiring. As shown in FIG. 3, the output connector unit 72 is provided on the side surface of the housing H that is closer to the reactor 21. Specifically, the output connector unit 72 is provided on the side surface 30b of the upper housing unit 30 that is closer to the reactor 21. The side surface 30b of the upper housing unit 30 is an example of the "side surface of the housing that is closer to the reactor" in the claims.

In the first embodiment, as described above, the wiring and devices constituting the main circuit for power conversion including the first main circuit section 10 and the second main circuit section 11 are arranged inside the housing H in order from the input side to the output side of the main circuit in accordance with the order of electrical connections of the main circuit (see FIG. 7). Note that the wiring V1, bus bar B1, bus bar B2, wiring V2, wiring V3, bus bar B3, bus bar B4, wiring V4, wiring V5, and bus bar B5 are examples of "wiring constituting the main circuit" as described in the claims. Also, the semiconductor switching element 10a, diode 11a, transformer 20, and reactor 21 are examples of "devices constituting the main circuit" as described in the claims.

Inside the housing H, from the input side to the output side of the main circuit, the filter section 12, the first main circuit section 10, the transformer 20, the second main circuit section 11, and the reactor 21 are arranged in this order. More specifically, from the input side to the output side of the main circuit, the input connector section 71, the wiring V1, the connector CN, the filter section 12 (filter board PB2), the bus bar B1, the first main circuit section 10 (main circuit board PB1 and semiconductor switching element 10a), the bus bar B2, the wiring V2, the transformer 20, the wiring V3, the bus bar B3, the second main circuit section 11 (diode 11a), the bus bar B4, the wiring V4, the reactor 21, the wiring V5, the bus bar B5, and the output connector section 72 are arranged in this order. Additionally, the wiring and devices that make up the main circuit are arranged inside the housing H so that the input connector section 71 and the output connector section 72 are at the ends on the X1 direction side, and the transformer 20 and wiring V2 are at the ends on the X2 direction side inside the housing H, folded back inside the housing H.

(Configuration for cooling inside the housing)
3, in the intermediate housing portion 40, a blower portion 60 is disposed on the side where the reactor 21 is disposed, and an exhaust port 41 through which cooling air is exhausted is disposed on the side where the transformer 20 is disposed. The blower portion 60 is configured to blow cooling air to the upper heat dissipation fins 82 (upper cooling portion 80) and the lower heat dissipation fins 92 (lower cooling portion 90) between the upper housing portion 30 and the lower housing portion 50.

The upper heat dissipation fins 82 and the lower heat dissipation fins 92 are arranged inside the intermediate housing 40. In addition, the air blower 60 is arranged on one end side (X1 direction side) of the intermediate housing 40 in the direction in which the cooling air flows. The air blower 60 is configured to blow cooling air to the upper heat dissipation fins 82 and the lower heat dissipation fins 92. In addition, an exhaust port 41 through which the cooling air is exhausted is arranged on the other end side (X2 direction side) of the intermediate housing 40. The upper heat dissipation fins 82 protrude downward from the Z2 direction side of the recess 31 of the upper housing 30, and the lower end of the upper heat dissipation fins 82 is arranged inside the intermediate housing 40.

The lower cooling section 90 (lower cooling main body section 91, lower heat dissipation fins 92) is disposed on the Z1 direction side of the lower housing section 50, and the entire lower cooling section 90 is disposed inside the intermediate housing section 40. The lower cooling section 90 is also disposed on the upper surface 50a (see FIG. 3) of the lower housing section 50. The exhaust port 41 is composed of multiple holes provided on the side surface 40b on the X2 direction side of the intermediate housing section 40. Unlike the upper housing section 30 and the lower housing section 50, outside air is introduced into the intermediate housing section 40. In other words, the intermediate housing section 40 is not sealed.

Furthermore, the intermediate housing part 40 and the space SP3 on the Z2 direction side of the recess 31 that communicates with the intermediate housing part 40 form a flow path A through which the cooling air flows. When viewed from the Y direction, the flow path A has a hat shape (step shape).

In the first embodiment, the reactor 21 is disposed in the flow path A between the air blower 60 and the convex lower housing part 50. The transformer 20 is disposed in the flow path A between the convex lower housing part 50 and the exhaust port 41. The reactor 21 and the transformer 20 are relatively heavy, and therefore disposed in the lower part of the power conversion device 100. Specifically, the reactor 21 is mounted on the surface 40a on the Z2 direction side of the intermediate housing part 40, which corresponds to the area between the air blower 60 and the lower housing part 50. The transformer 20 is mounted on the surface 40a on the Z2 direction side of the intermediate housing part 40, which corresponds to the area between the lower housing part 50 and the exhaust port 41. In the first embodiment, the reactor 21, which is smaller in size in the vertical direction than the transformer 20, is disposed upstream of the cooling air, and therefore the reactor 21 can be efficiently cooled.

In the first embodiment, the cooling air (arrow C in FIG. 3) is configured to flow from the blower 60 over the convex lower housing part 50, and through the upper cooling part 80 and the lower cooling part 90 to the downstream side (Z2 direction side) in the direction in which the cooling air flows of the convex lower housing part 50.

[Effects of the First Embodiment]
In the first embodiment, the following effects can be obtained.

In the first embodiment, as described above, the wiring and devices constituting the main circuit for power conversion including the first main circuit section 10 and the second main circuit section 11 are arranged in the housing H in order from the input side to the output side of the main circuit in the order of electrical connections of the main circuit. A part of the wiring constituting the main circuit is provided from the inside to the outside of each of the upper housing section 30 and the lower housing section 50 that accommodate the first main circuit section 10 and the second main circuit section 11, respectively. As a result, the wiring and devices constituting the main circuit are arranged in order from the input side to the output side of the main circuit in the housing H in the order of electrical connections of the main circuit, thereby shortening the wiring length constituting the main circuit. As a result, it is possible to provide a power conversion device 100 that can suppress an increase in the weight of the device due to an increase in the wiring length and the number of wirings. In addition, by arranging the wiring and devices in the order of electrical connections of the main circuit, the arrangement of the wiring and devices is not complicated, and assembly work can be easily performed.

In the first embodiment, as described above, the first main circuit section 10, the transformer 20, the second main circuit section 11, and the reactor 21 are arranged in this order from the input side to the output side of the main circuit inside the housing H. This allows the first main circuit section 10, the transformer 20, the second main circuit section 11, and the reactor 21 to be arranged along the current flow of the main circuit, so that the length of the wiring connecting each of the first main circuit section 10, the transformer 20, the second main circuit section 11, and the reactor 21 can be shortened. As a result, the increase in the weight of the device due to the increase in the length of the wiring connecting each of the first main circuit section 10, the transformer 20, the second main circuit section 11, and the reactor 21 can be suppressed.

In the first embodiment, as described above, the upper housing section 30 and the lower housing section 50 are arranged so as to overlap in the vertical direction, and the housing H includes the intermediate housing section 40 in which the transformer 20 and the reactor 21 are arranged. The intermediate housing section 40 is arranged below the upper housing section 30, and the transformer 20 is electrically connected to the first main circuit section 10 by wiring V2 arranged in the vertical direction so as to straddle the boundary between the upper housing section 30 and the intermediate housing section 40. As a result, the upper housing section 30 and the lower housing section 50 overlap in the vertical direction, which makes it possible to suppress an increase in the installation area (bottom area) of the power conversion device 100.

In the first embodiment, as described above, the lower housing section 50 is disposed below the upper housing section 30, and the intermediate housing section 40 is disposed so as to cover the upper and sides of the lower housing section 50. The transformer 20 and the reactor 21 are disposed so as to sandwich the lower housing section 50 therebetween, and are electrically connected to the second main circuit section 11 by wiring (wiring V3 and wiring V4) that is provided so as to straddle the boundary between the intermediate housing section 40 and the lower housing section 50. This allows the transformer 20 and the reactor 21, which generate a relatively large amount of heat, to be spaced apart from each other, thereby suppressing a decrease in the heat dissipation efficiency of the transformer 20 and the reactor 21.

In the first embodiment, as described above, the upper housing part 30 is configured to hermetically house the first main circuit part 10, and the lower housing part 50 is configured to hermetically house the second main circuit part 11. This allows the first main circuit part 10 and the second main circuit part 11 to be hermetically housed in the upper housing part 30 and the lower housing part 50, respectively, so that the first main circuit part 10 and the second main circuit part 11 can be protected from dust and moisture. In addition, the transformer 20 and the reactor 21 are disposed in the intermediate housing part 40, and can be disposed outside the hermetically sealed upper housing part 30 and lower housing part 50, so that they can be effectively cooled by the outside air.

In the first embodiment, as described above, the filter unit 12 is housed in the upper housing unit 30 and is electrically connected to the first main circuit unit 10 by wiring provided inside the upper housing unit 30. Inside the housing H, the filter unit 12, the first main circuit unit 10, the transformer 20, the second main circuit unit 11, and the reactor 21 are arranged in this order from the input side to the output side of the main circuit. This allows the filter unit 12, the first main circuit unit 10, the transformer 20, the second main circuit unit 11, and the reactor 21 to be arranged along the current flow of the main circuit, so that the length of the wiring connecting each of the filter unit 12, the first main circuit unit 10, the transformer 20, the second main circuit unit 11, and the reactor 21 can be shortened. As a result, the increase in the weight of the device due to the increase in the length of the wiring connecting each of the filter unit 12, the first main circuit unit 10, the transformer 20, the second main circuit unit 11, and the reactor 21 can be suppressed.

In addition, in the first embodiment, as described above, the input connector unit 71 is provided on the side surface 30b of the upper housing unit 30 that is closer to the filter unit 12, which is the side surface of the housing H that is closer to the filter unit 12. This makes it possible to shorten the length of the wiring connecting the input connector unit 71 and the filter unit 12. As a result, it is possible to suppress an increase in the weight of the device due to an increase in the length of the wiring connecting the input connector unit 71 and the filter unit 12.

In addition, in the first embodiment, as described above, the output connector unit 72 is provided on the side surface 30b of the upper housing unit 30, which is the side surface of the housing H that is closer to the reactor 21, that is, the side surface closer to the filter unit 12. This makes it possible to shorten the length of the wiring connecting the output connector unit 72 and the reactor 21. As a result, it is possible to suppress an increase in the weight of the device due to an increase in the length of the wiring connecting the output connector unit 72 and the reactor 21.

In the first embodiment, as described above, the control unit 70 is housed in the upper housing part 30 together with the first main circuit part 10 including the semiconductor switching element 10a, and the second main circuit part 11 includes the diode 11a that rectifies AC power to DC power, and is housed in the lower housing part 50 different from the upper housing part 30 in which the control unit 70 is housed. As a result, by housing the control unit 70 in the upper housing part 30 together with the first main circuit part 10 including the semiconductor switching element 10a, the wiring length connecting the semiconductor switching element 10a and the control unit 70 can be shortened compared to when the control unit 70 is housed in a part other than the upper housing part 30. As a result, the increase in the weight of the device due to the increase in the wiring length connecting the semiconductor switching element 10a and the control unit 70 can be suppressed. In addition, since the diode 11a is not controlled by the control unit 70, there is no need to provide wiring connecting the diode 11a and the control unit 70, and even if the diode 11a is housed in the lower housing part 50 in which the control unit 70 is not housed, there is no increase in the wiring length and the number of wiring. As a result, the increase in wiring length and the increase in device weight due to an increase in the number of wiring can be further suppressed.

In the first embodiment, as described above, the upper heat dissipation fins 82 are arranged in the intermediate housing 40, and the lower heat dissipation fins 92 are arranged in the intermediate housing 40 so as to face the upper heat dissipation fins 82 and be spaced apart from the upper heat dissipation fins 82 at a predetermined interval. The intermediate housing 40 has the blower 60 arranged on the side where the reactor 21 is arranged, and the exhaust port 41 through which the cooling air is exhausted arranged on the side where the transformer 20 is arranged. As a result, the upper heat dissipation fins 82 and the lower heat dissipation fins 92 can be cooled by the cooling air blown by the blower 60 and ventilating the inside of the intermediate housing 40, thereby cooling the first main circuit section 10 and the second main circuit section 11, and therefore the first main circuit section 10 and the second main circuit section 11 can be efficiently cooled. In addition, by arranging the air blower 60 on the side where the reactor 21 is located and the exhaust port 41 on the side where the transformer 20 is located, the reactor 21, which generates more heat than the transformer 20, is located upstream of the cooling air, so that the reactor 21 can be cooled efficiently.

[Second embodiment]
The configuration of a power conversion device 300 according to the second embodiment will be described with reference to Fig. 8. The power conversion device 300 according to the second embodiment differs from the first embodiment in that it includes a capacitor 322 between the output connector unit 72 and the reactor 21. The capacitor 322 is a smoothing capacitor, and the reactor 21 and the capacitor 322 form a smoothing circuit. The capacitor 322 is housed in the upper housing unit 30.

The capacitor 322 is electrically connected to the reactor 21 via the wiring V305. The capacitor 322 is also electrically connected to the bus bar B5, which is electrically connected to the output connector unit 72, via the wiring V306. That is, the capacitor 322 is electrically connected to the output connector unit 72 via the wiring V306 and the bus bar B5.

In the second embodiment, the wiring and devices constituting the main circuit for power conversion, including the first main circuit section 10 and the second main circuit section 11, are arranged in the housing H in the same order as the power conversion device 100 of the first embodiment, from the input side to the output side of the main circuit, in accordance with the order of electrical connections of the main circuit.

In the power conversion device 300, the filter section 12, the first main circuit section 10, the transformer 20, the second main circuit section 11, the reactor 21 and the capacitor 322 are arranged in this order from the input side to the output side of the main circuit inside the housing H.

The other configurations and effects of the second embodiment are the same as those of the first embodiment.

The power conversion device 100 according to the first embodiment and the power conversion device 300 according to the second embodiment may also be combined.

[Variations]
It should be noted that the embodiments disclosed herein are illustrative and not restrictive in all respects. The scope of the present invention is indicated by the claims, not by the description of the embodiments above, and further includes all modifications (variations) within the meaning and scope of the claims.

For example, in the first and second embodiments described above, the intermediate housing section 40 (third housing section) is arranged to cover the upper and sides of the lower housing section 50 (second housing section), but the present invention is not limited to this. In the present invention, as in the power conversion device 400 according to the modified example shown in FIG. 9, the third housing section 440 may be arranged below the first housing section 430 so as to cover only the upper side of the second housing section 450.

In the above first and second embodiments, the transformer 20 and the reactor 21 are arranged in the intermediate housing section 40 (third housing section) of the housing H, but the present invention is not limited to this. In the present invention, the transformer and the reactor may be arranged in a portion other than the third housing section (such as the first housing section, the second housing section, and the outside of the housing of the power conversion device). Also, only one of the transformer and the reactor may be arranged in the third housing section.

In addition, in the above first and second embodiments, the upper housing unit 30 (first housing unit) and the lower housing unit 50 (second housing unit) are arranged so as to overlap in the vertical direction, but the present invention is not limited to this. In the present invention, the first housing unit and the second housing unit may be arranged so as to overlap in the horizontal direction.

In addition, in the above first and second embodiments, the lower housing part 50 (second housing part) that hermetically houses the second main circuit part 11 is disposed below the upper housing part 30 (first housing part) that hermetically houses the first main circuit part 10, but the present invention is not limited to this. In the present invention, the second housing part that hermetically houses the second main circuit part may be disposed above the first housing part that hermetically houses the first main circuit part.

In the above first and second embodiments, the transformer 20 and the reactor 21 are respectively arranged on one side and the other side of the opposing sides of the lower housing part 50 (second housing part) inside the intermediate housing part 40 (third housing part), but the present invention is not limited to this. In the present invention, the transformer and the reactor may be arranged on the same side of the second housing part inside the third housing part. Also, the transformer and the reactor may be arranged so as to sandwich the second housing part between them in the vertical direction.

In the above first and second embodiments, the filter unit 12 is disposed in the upper housing part 30 (first housing part) of the housing H, but the present invention is not limited to this. In the present invention, the filter unit may be disposed in a part other than the first housing part (such as the second housing part, the third housing part, or the outside of the housing of the power conversion device).

In the above first and second embodiments, the input connector unit 71 is provided on the side surface 30b of the upper housing unit 30 (first housing unit) of the housing H, which is closer to the filter unit 12, but the present invention is not limited to this. In the present invention, the input connector unit may be provided on the side surface of the second housing unit, which is closer to the filter unit. In addition, the input connector unit may be provided on the top and bottom surfaces of the housing, i.e., the top surface of the first housing unit and the bottom surface of the second housing unit.

In the above first and second embodiments, the output connector unit 72 is provided on the side surface 30b of the upper housing unit 30 (first housing unit) of the housing H, which is closer to the filter unit 12, but the present invention is not limited to this. In the present invention, the output connector unit may be provided on the side surface of the second housing unit, which is closer to the filter unit. Also, the output connector unit may be provided on the top and bottom surfaces of the housing, i.e., the top surface of the first housing unit and the bottom surface of the second housing unit.

In addition, in the first and second embodiments, an example is shown in which the first main circuit section 10 includes a semiconductor switching element 10a and the second main circuit section 11 includes a diode 11a, but the present invention is not limited to this. In the present invention, the first main circuit section may include a diode and the second main circuit section may include a semiconductor switching element.

In addition, in the above first and second embodiments, the lower heat dissipation fins 92 (second heat dissipation fins) face the upper heat dissipation fins 82 (first heat dissipation fins) and are arranged in the intermediate housing 40 (inside the third housing) so as to be spaced a predetermined distance from the upper heat dissipation fins 82, but the present invention is not limited to this. In the present invention, the first heat dissipation fins (first cooling section) and the second heat dissipation fins (second cooling section) may be arranged side by side in the horizontal direction.

In addition, in the first and second embodiments, an example is shown in which the intermediate housing 40 (third housing) has the blower 60 arranged on the side where the reactor 21 is arranged, and the exhaust port 41 through which the cooling air is exhausted arranged on the side where the transformer 20 is arranged, but the present invention is not limited to this. In the present invention, the third housing may have the exhaust port 41 arranged on the side where the reactor 21 is arranged, and the blower 60 arranged on the side where the transformer 20 is arranged.

In addition, in the first and second embodiments, the first main circuit section 10 and the filter section 12 are formed on different printed circuit boards (PCBs), but the present invention is not limited to this. In the present invention, the main circuit section and the filter section may be formed on the same printed circuit board.

In the above first and second embodiments, the upper housing section 30 (first housing section) is configured to hermetically house the first main circuit section 10, and the lower housing section 50 (second housing section) is configured to hermetically house the second main circuit section 11, but the present invention is not limited to this. In the present invention, the first housing section and the second housing section may have, for example, an opening, and may not house the first main circuit section and the second main circuit section in a hermetically sealed manner. Also, the first housing section may not be hermetically sealed, and only the second housing section may be hermetically sealed. And the second housing section may not be hermetically sealed, and only the first housing section may be hermetically sealed.

REFERENCE SIGNS LIST 10 First main circuit section 10a Semiconductor switching element 11 Second main circuit section 11a Diode 12 Filter section 20 Transformer 21 Reactor 30 Upper housing section (first housing section)
30b (Upper housing part) side (side closer to the reactor of the housing, side closer to the filter part of the housing)
40 Intermediate housing portion (third housing portion)
50 Lower housing part (second housing part)
60 Blower section 41 Exhaust port 70 Control section 71 Input connector section 72 Output connector section 80 Upper cooling section (first cooling section)
82 Upper heat dissipation fin (first heat dissipation fin)
90 Lower cooling section (second cooling section)
92 Lower heat dissipation fin (second heat dissipation fin)
100, 300 Power conversion device

Claims (8)

a first main circuit unit that converts electric power;
A second main circuit unit that converts the power converted by the first main circuit unit;
a transformer that converts a voltage between the first main circuit unit and the second main circuit unit;
a reactor to which the power converted by the second main circuit portion is input;
a housing including a first housing portion that houses the first main circuit portion, a second housing portion that houses the second main circuit portion, and a third housing portion in which the transformer and the reactor are disposed,
Wiring and devices constituting a main circuit for power conversion including the first main circuit section and the second main circuit section are arranged inside the casing in the order of electrical connection of the main circuit from the input side to the output side of the main circuit, the first main circuit section, the transformer, the second main circuit section, and the reactor,
a part of wiring constituting the main circuit is provided from the inside to the outside of each of the first housing portion and the second housing portion that accommodate the first main circuit portion and the second main circuit portion,
The second housing portion is disposed below the first housing portion ,
the third housing portion is disposed below the first housing portion and above the second housing portion,
A power conversion device in which the transformer is electrically connected to the first main circuit unit by wiring arranged in the vertical direction so as to straddle the boundary between the first housing unit and the third housing unit. the third housing portion is disposed so as to cover an upper portion and a side portion of the second housing portion,
The power conversion device according to claim 1, wherein the transformer and the reactor are arranged so as to sandwich the second housing portion therebetween, and are electrically connected to the second main circuit portion by wiring provided so as to straddle the boundary between the third housing portion and the second housing portion. The first housing portion is configured to hermetically house the first main circuit portion,
The power conversion device according to claim 2 , wherein the second housing portion is configured to hermetically house the second main circuit portion. A filter unit is provided on an input side of the first main circuit unit,
the filter unit is accommodated in the first housing unit and is electrically connected to the first main circuit unit by wiring provided inside the first housing unit;
4. The power conversion device according to claim 3, wherein the filter section, the first main circuit section, the transformer, the second main circuit section, and the reactor are arranged in this order from an input side to an output side of the main circuit inside the housing. an input connector unit electrically connected to an external wiring and inputting power from the external wiring to the filter unit;
The power conversion device according to claim 4 , wherein the input connector portion is provided on a side surface of the housing that is closer to the filter portion. an output connector unit electrically connected to an external wiring and configured to output the power converted by the main circuit to the external wiring;
The power conversion device according to claim 1 , wherein the output connector portion is provided on a side surface of the housing that is closer to the reactor. the first main circuit portion includes a semiconductor switching element that converts DC power into AC power;
A control unit that controls the semiconductor switching element is further provided.
The control unit is accommodated in the first housing together with the first main circuit unit,
The power conversion device according to any one of claims 2 to 6, wherein the second main circuit portion includes a diode that rectifies AC power to DC power, and is housed in the second housing portion different from the first housing portion in which the control portion is housed. a first cooling section including a first heat dissipation fin and on which the first main circuit section is placed;
a second cooling section including a second heat dissipation fin and on which the second main circuit section is placed;
a blower configured to blow cooling air to the first heat dissipation fins and the second heat dissipation fins,
the first heat dissipation fin is disposed within the third housing portion,
the second heat dissipation fin is disposed in the third housing portion so as to face the first heat dissipation fin and be spaced a predetermined distance from the first heat dissipation fin,
The power conversion device according to claim 7 , wherein the blower is arranged on a side of the third housing portion where the reactor is arranged, and an exhaust port through which the cooling air is exhausted is arranged on a side of the third housing portion where the transformer is arranged.

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