JP2020010469A - Power control unit - Google Patents

Abstract

To suppress noise interference in a power control unit in which a power supply system elements including a vehicle charger including a motor as a propulsion source are integrated.SOLUTION: An AC filter 41 which filters switching noise generated by switching of an ACDC converter 39 at the time of charging a high voltage battery at a commercial power supply port CP side is stored in an accommodation unit 7 of a lower case 3 of a power control unit 1. Further, an inverter that converts DC power of the high-voltage battery into three-phase AC power to outputs it to a propulsion motor is accommodated in the accommodation unit 7 of the lower case 3. An ACDC converter 39 that converts AC power of commercial a power source input from a commercial power supply port CP into DC power of a voltage corresponding to the high voltage battery is accommodated in an accommodation unit 23 of an upper case 5 that is superposed on the lower case 3. An AC filter 41 is arranged so as to entirely overlap with the ACDC converter 39.SELECTED DRAWING: Figure 2

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 of a commercial power supply 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 for switching noise generated in the switching circuit may be arranged separately in separate spaces partitioned by walls. Has been proposed in the past.

  According to this proposal, noise interference between the switching circuit and the filter circuit can be suppressed (for example, Patent Document 1).

International Publication No. WO 2017/022478

  In the past proposals described above, countermeasures against noise interference in the charger of the electric vehicle are being studied. On the other hand, with respect to electric vehicles, miniaturization and high-density of mounted components are being promoted by realizing a power control unit in which a charger is integrated 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 above-mentioned configuration proposed in the past.

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

To achieve the above object, a power control unit according to one aspect of the present invention includes:
A switching circuit that converts input power into charging power for a battery, and a charger having a filter circuit that filters switching noise of the switching circuit at an input side of the switching circuit;
A power module that converts the power of the battery into power for supply to a load,
An isolation wall for physically and magnetically separating 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;
Is provided.

  ADVANTAGE OF THE INVENTION According to this invention, the noise interference in the power control unit which integrated the electric power system element containing the charger of the vehicle which contains a motor as a propulsion source can be aimed at.

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

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a partially exploded perspective view showing a power control unit of an electric vehicle according to an 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 the present embodiment, a power control unit mounted on a plug-in hybrid vehicle (PHEV) will be described.

  The power control unit 1 of the present embodiment shown in FIG. 1 includes a charge / discharge of a high-voltage battery (not shown) serving as a power source of a propulsion motor (not shown) of the electric vehicle and a low-voltage load (not shown) of the electric vehicle. In this case, elements related to charging of a low-voltage battery (not shown) serving as a power supply of the auxiliary device are collectively provided.

  The power control unit 1 has a lower case 3 and an upper case 5 superposed thereon. The lower case 3 and the upper case 5 are formed, for example, by casting a metal material having a magnetic shielding function such as aluminum and having a 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 which is open on the bottom surface. The opening of the housing 7 is closed by the lid 9. On the ceiling surface 12 (corresponding to an isolation wall in the claims) of the lower case 3, a wiring hole 11 communicating with the housing 7 is formed.

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

  As shown in FIG. 2, the upper case 5 has a housing portion 23 that opens on the bottom surface. The opening of the housing 23 is closed by the ceiling surface 12 of the lower case 3 on which the upper case 5 is stacked. In addition, working openings 25 and 27 are formed in the ceiling surface 24 of the upper case 5 to expose parts and the like housed in the housing part 23. The working openings 25 and 27 are closed by lids 29 and 31.

  Port mounting holes 33 and 35 are formed on one of the side surfaces of the upper case 5 as shown in FIG. The quick charging port QP is attached to the port attachment hole 33. The high-voltage battery port HBP is mounted in the port mounting hole 35.

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

  The plug-in charger (normal charger) CHG (corresponding to a charger in the claims) has an ACDC converter 39 and an AC (AC) filter 41.

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

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

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

  As shown in FIG. 2, the AC filter 41 is housed in the housing 7 (corresponding to a second space in the claims) of the lower case 3. The AC filter 41 of the housing 7 is arranged close to the side surface 42 of the lower case 3 where the commercial power port CP is provided. The ACDC converter 39 of the upper case 5 and the AC filter 41 of the lower case 3 are connected by a cable 43 passing through the wiring hole 11 of the 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 7 of the lower case 3 as shown in FIG.

  The smoothing capacitor smoothes the current when driving a later-described inverter or a later-described DCDC converter 37 of the power module PM. The smoothing capacitor smoothes the current when the AC-DC converter 39 of the plug-in charger CHG converts AC power from a commercial power supply into DC power.

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

  Alternatively, the DC / DC converter 37, which will be described later, converts the DC power into a low voltage and outputs the low voltage from the low voltage battery port LBP to a low voltage battery (not shown). The output to the DCDC converter 37 is allowed.

  Further, the main relay allows charging of the high-voltage battery during quick charging and normal charging.

  Then, when the electric vehicle is in a state other than these, 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, a driver circuit of the DCDC converter 37, the ACDC converter 39 of the plug-in charger CHG, and a driver circuit of an inverter described later of the power module PM. And other operations are controlled.

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

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

  This inverter does not operate when charging a high-voltage battery (not shown). For this reason, even if the power module PM is arranged adjacent to the AC filter 41 for removing the switching noise of the ACDC converter 39 generated when charging the high-voltage battery, it does not adversely affect the operation of the inverter.

  In the present embodiment, the configuration in which the inverter converts to three-phase AC power has been described as an example. However, the inverter may convert to three-phase or more polyphase AC (the configuration of the inverter in that case is omitted). ).

  Each power semiconductor switching element can be constituted by, for example, an IGBT (Insulated Gate Bipolar Transistor, insulated gate bipolar transistor). Further, each power semiconductor switching element can be constituted by a power MOSFET.

  When each power semiconductor switching element is an IGBT or a power MOSFET, the drive circuit is configured by a gate drive circuit.

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

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

  As shown in FIG. 3, the smoothing module SM including the controller for controlling the operation of the driver circuit of the DCDC converter 37 is disposed at a location more distant from the AC filter 41 than the DCDC converter 37 in the housing 7 of the lower case 3. I have.

  The bus bar module BM includes a bus bar (not shown) that connects the ACDC converter 39 of the plug-in charger CHG with the quick charge port QP and the high-voltage battery port HBP, and a quick charge port from the ACDC converter 39 when the quick charge port QP is opened. And a QC relay (not shown) for interrupting the QP.

  In the power control unit 1 of the present embodiment configured as described above, when the upper case 5 is overlaid on the lower case 3, the entirety of the AC filter 41 accommodated in the accommodating portion 7 of the lower case 3 becomes the accommodating 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 length of the wiring hole 11 passing therethrough can be reduced. This makes it possible to reduce the influence of noise due to the switching of the ACDC converter 39 on the signal of the cable 43.

  Further, in the power control unit 1 of the present embodiment, the smoothing module SM is disposed in the accommodating portion 7 of the lower case 3 at a position separated from the DC filter 37 by the AC filter 41.

  Therefore, the influence 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.

  Further, a low-side voltage transformed by the DCDC converter 37 is provided on a side surface 42 different from the side surface 44 of the lower case 3 provided with the commercial power supply port CP for suppressing the propagation of the switching noise of the ACDC converter 39 to the commercial power supply side by the AC filter 41. A low voltage battery port LBP for outputting a DC voltage for a voltage battery is provided.

  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.

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

Reference Signs List 1 power control unit 3 lower case 5 upper case 7 accommodation section (second space)
9 Lid 11 Wiring hole 12 Lower case ceiling (isolation wall)
13 Water jacket 15 Cooling water (cooling liquid)
17 flow path 19 water inlet port 21 water outlet port 23 accommodation 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 Side of lower case (side wall where input connector is placed)
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 (5)

It has a switching circuit (39) for converting input power to charging power for a battery, and a filter circuit (41) for filtering switching noise of the switching circuit (39) at an input side of the switching circuit (39). A charger (CHG),
A power module (PM) for converting the power of the battery into power for supply to a load;
The first space (23) in which the switching circuit (39) is arranged and the second space (7) in which the filter circuit (41) and the power module (PM) are arranged are physically and magnetically isolated. A wall (12),
A power control unit (1) comprising:   At least a part of the filter circuit (41) is located at a position overlapping the switching circuit (39) in the stacking direction of the first space (23) and the second space (7) with the isolation wall (12) interposed therebetween. The power control unit (1) according to claim 1, which is arranged.   The said separation wall (12) has the flow path (17) in which the cooling liquid (15) which cools the said 1st space (23) and the said 2nd space (7) flows inside. The described power control unit (1).   A DC-DC converter (37) for transforming the charging power; and a control circuit (SM) for controlling the operation of the DC-DC converter (37). The DC-DC converter (37) and the control circuit (SM) Is disposed in the second space (7), and the control circuit (SM) is disposed at a position more distant from the filter circuit (41) than the DCDC converter (37). The power control unit (1) according to 2 or 3.   The input connector (CP) of the power input to the charger (CHG) is connected to the DCDC with the filter circuit (41) interposed between the side walls of the housing (3) having the second space (7) therein. The power control unit (1) according to claim 4, wherein the power control unit (1) is arranged on a side wall (42) located on a side opposite to a side of the converter (37).

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