JP4014152B2 - Power control unit for electric vehicles - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an electric vehicle power control unit and a high voltage terminal block applied to an electric vehicle equipped with a traveling motor such as a fuel cell electric vehicle.
[0002]
[Prior art]
In view of environmental problems, energy problems, etc., electric vehicles that run by driving a driving motor (hereinafter referred to as “traveling motor”) with a storage battery such as a battery or a fuel cell attracting attention. This electric vehicle is equipped with an electric vehicle power control unit (hereinafter referred to as “PCU”) in addition to a battery and a traveling motor. FIG. 1 is a schematic perspective view from the side of a vehicle equipped with a PCU in a conventional example (and an embodiment according to the present invention). As shown in FIG. 1, for example, in the case of a fuel cell electric vehicle (hereinafter referred to as “vehicle”) 100 equipped with a fuel cell 102, a capacitor 103, and a travel motor 104, the PCU 101 includes an inverter for driving the travel motor 104 ( A power drive unit (hereinafter referred to as “PDU”), a voltage control unit (hereinafter referred to as “VCU”) for adjusting a voltage between the fuel cell 102 and the capacitor 103 are incorporated.
[0003]
Further, in the vehicle 100, a fuel cell 102 and a capacitor 103 are disposed below the floor of the passenger compartment, a traveling motor 104 is disposed in the motor compartment, and a PCU 101 is disposed above the traveling motor 104 (reference W). Indicates a drive wheel). In addition, the components, that is, the fuel cell 102, the capacitor 103, the traveling motor 104, and the PCU 101 are connected by a high voltage cable, and power is exchanged between them.
[0004]
FIG. 4 is a block diagram showing a connection state of a high voltage cable and a position of a high voltage terminal in a conventional vehicle. As shown in FIG. 4, a VCU 108 (voltage control unit), an INV 109 (inverter), and the like are arranged in the PCU 101, and a high-voltage terminal block 106 that connects the INV 109 and the MOT 104 (three-phase motor) is provided.
A high voltage cable connecting the VCU 108 of the PCU 101 and the fuel cell 102 is referred to as an FC cable. A high voltage cable connecting the PCU 101 and the capacitor 103 is called a CAPA cable, and a high voltage cable connecting the INV 109 and the traveling motor 104 is called an MOT cable.
Incidentally, as shown in FIG. 1, the PCU 101 is disposed in the vicinity of the traveling motor 104 in order to reduce the power loss by shortening the length of the MOT cable.
[0005]
FIG. 5 is a schematic diagram of a three-sided view showing the arrangement of the high-voltage box 110 and the traveling motor 104. FIG. 5 (a) is a configuration from the top of the PCU 101 with the lid of the PCU 101 disposed in the motor chamber removed from the front of the vehicle. FIG. 5B is a front view of the PCU and the traveling motor, and FIG. 5C is a right side view of FIG.
As shown in FIG. 5A, the high-voltage box 110 is provided with INV109, VCU108, and the like, which are high-piezoelectric components, and a high-voltage terminal block 106 that connects the INV109 and the MOT104. The conventional high-voltage terminal block 106 is disposed at the center of the high-voltage box 110, and the high-voltage terminal block 106 is covered with a cover 106a made of an insulating material to ensure insulation.
[0006]
[Patent Document 1]
Not applicable for patent and non-patent literature.
[0007]
[Problems to be solved by the invention]
However, although the conventional high-voltage terminal block 106 is arranged in the high-voltage box 110, when the vehicle 100 collides from the front direction or the rear direction, the high-voltage box 110 is deformed or damaged. There is a problem in that there is a risk that the conductive parts may penetrate through the insulating cover 106a and short-circuit. Therefore, it is necessary to develop a new insulating cover with high rigidity, and there are problems in verifying these new parts, reducing costs, miniaturization design, improving assemblability and the like.
[0008]
Therefore, the present invention does not cause a short circuit of the high-voltage terminal block even when the motor chamber is deformed due to a collision in the front-rear direction, etc., thereby reducing costs, miniaturizing design, improving assemblability, and improving reliability. It is an object of the present invention to provide a power control unit for an electric vehicle that can be used.
[0009]
[Means for Solving the Problems]
Electrical vehicle power control unit of the invention described in claim 1 of the present invention, electricity voltage control unit for voltage adjustment between the inverter and the power supply for driving the motor driven in the high-pressure box is built a power control unit for a vehicle, high-voltage terminal block for connecting cables to each other and, and a strength member fixed to the outer surface of the side wall of the high-pressure box, pressure box facing the strength member across said side wall The high-voltage terminal block is provided close to the inner surface, a part of the strength member is provided to extend inside the side wall, and the high-voltage terminal block is disposed above the part of the strength member. And
[0010]
According to the first aspect of the present invention, the electric vehicle power control unit that performs power supply control is housed in the high-pressure box. In other words, the strength member is fixed to the outer wall surface of the high-voltage box, and the high-voltage terminal block is disposed on the inner wall surface of the region guarded by the strength member. There is no damage, and there is no fear of short-circuiting due to penetration of other parts, an insulating cover for ensuring insulation is unnecessary, and reliability can be improved and quality assurance can be ensured.
As a result, it is possible to reduce man-hours, reduce costs, realize a miniaturized design, and the like together with the provision of an electric vehicle power control unit capable of quality assurance and improved reliability.
The term “power source” used in the present invention is determined according to the vehicle to which the power control unit (PCU) of the present invention is applied, and means that it includes power storage means and power supply means. For example, in a vehicle equipped with a fuel cell, a fuel cell or a fuel cell and a battery (capacitor) correspond to a power source. In a hybrid vehicle and an electric vehicle, a battery corresponds to a power source. In a solar car, a solar panel and a battery serve as a power source. Applicable. In the present invention, these are collectively referred to as a power source.
[0011]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 is a schematic view seen from the side of a vehicle on which a PCU is mounted. FIG. 2 is a block diagram showing the connection state of the high voltage cable and the position of the high voltage terminal in the vehicle of FIG.
The term “high voltage cable” used in the present invention means to include all cables that are electrically connected to other devices via the PCU 1. That is, in the following embodiment, a vehicle as shown in FIG. 1 described in the related art will be mainly described as a representative example of an electric vehicle. However, the high voltage cable in the present invention is the same as the MOT cable in the prior art. It is not limited to FC cables and CAPA cables. For example, instead of a CAPA cable, another power supply device, for example, a cable connected to a solar cell, instead of another power storage means, for example, a cable connected to a secondary battery or an FC cable, is also a high voltage cable according to the present invention.
[0012]
As shown in FIG. 1, a PCU (Power Control Unit) 1 of the present embodiment is disposed on an upper part of a traveling motor 4 installed in a motor chamber located in the front part of the vehicle EV. The reason why the PCU 1 is arranged in the upper part of the traveling motor 4 is to shorten the length of the motor chamber in the front-rear direction and to shorten the length of the MOT cable. The basic layout of each component in the electric vehicle EV (Electric Vehicle) of this embodiment, that is, the layout of the PCU 1, the fuel cell 2, the capacitor 3, and the traveling motor 4 may be the same as or different from that of the conventional example. May be.
[0013]
As shown in FIG. 2, the fuel cell 2 is a direct current, and is connected to a VCU 8 (voltage control unit) disposed in the high-pressure box 10 by an FC cable, and the VCU 8 and INV 9 (inverter) are connected. Since three-phase alternating current is convenient for driving the motor, direct current is converted into alternating current by INV9. The high voltage terminal block 6 is a terminal block for connecting the INV 9 and the MOT cable from the MOT 4.
[0014]
FIG. 3 is a schematic diagram of a three-sided view showing the arrangement of the high-voltage box 10 and the traveling motor 4, and FIG. 3 (a) shows the lid 10a viewed from the top of the PCU 1 disposed in the motor chamber from the front of the vehicle. The top view which shows the state removed, (b) is the front view which looked at PCU1 and the traveling motor 4 from the front, (c) is the right view with respect to (a).
As shown in FIG. 3A, the high-pressure box 10 that is the casing of the PCU 1 is made of an aluminum mold, and has a waterproof lid 10a. The high-pressure box 10 includes a VCU for the fuel cell 2, a PDU (power drive unit) for the traveling motor 4, an inverter for circulating the cooling water, an inverter for driving the supercharger, etc. (not shown), and constitutes the PCU 1. ing.
[0015]
Here, the layout of the high voltage cable in the motor chamber will be described.
As shown in FIG. 3A, the PCU 1 includes a connector case 13 on the right side of the vehicle (left side in the drawing) when viewed from the partition wall (occupant) side with respect to the vehicle interior. As shown in FIG. 3A, the connector case 13 includes three connectors for the MOT cable (three-phase), two connectors for the CAPA cable (single-phase), and two connectors for the FC cable (single-phase). )have. That is, in the PCU 1 of this embodiment, all the high voltage cables are connected by the connector case 13 provided on one side of the PCU 1, and the MOT cable and the like can be removed at the connector case 13 portion.
[0016]
As shown in FIG. 3 (b), a lid 10 a is fixed on the upper surface of the high-pressure box 10 to ensure water resistance, and the partition 13 a has a cross section that defines the connector case 13 inside the high-pressure box 10. It is L-shaped and has a length extending from the front wall surface of the high-pressure box 10 to the rear wall surface. Incidentally, a connector for removably locking an MOT cable or the like is attached to the partition 13a.
[0017]
Further, as shown in FIGS. 3B and 3C, the MOT cable extending downward from the PCU 1 is connected to the traveling motor 4 positioned immediately below the PCU 1. Further, as shown in FIG. 3B, the FC cable and the CAPA cable hang downward from the PCU 1, pass through the right side of the traveling motor 4 (left side in the drawing), and extend rearward. And is connected to the fuel cell 2 and the capacitor 3 as shown in the block diagram of FIG.
[0018]
As described above, the MOT cable, FC cable, and CAPA cable are retracted or offset to the right side of the travel motor 4 (right side with respect to the vehicle EV). Even if the travel motor 4 and / or the PCU 1 moves rearward and the gap between the partition and the vehicle interior becomes narrow, there is no problem in the operation of removing these cables from the PCU 1. Even if the traveling motor 4 moves backward in the motor chamber due to a collision or the like, the FC cable and the CAPA cable are not sandwiched between the partition walls between the traveling motor 4 and the vehicle interior (see FIG. 3C). This is different from the PCU 101 shown in FIG.
[0019]
In addition, as a high voltage cable such as a MOT cable, a conductor (tin-plated annealed copper wire) is insulated and protected by an insulator (crosslinked polyethylene), a braided shield (tinned annealed copper wire), and a sheath (PVC). Insulated braided shielded high-voltage wires are used. Incidentally, in this embodiment, the conductor cross-sectional area of the CAPA cable is smaller than the conductor cross-sectional area of the FC cable or the MOT cable.
[0020]
The strength of the high pressure box 10 of the PCU 1 will be described.
In order to give the high-pressure box 10 strength, the high-pressure box 10 is formed of a mold or a cut product, and the high-pressure box 10 is provided with a rib or the like (not shown). The wall surface is prevented from falling inward.
[0021]
Next, the strength member 7 will be described.
As shown in FIGS. 3 (a) and 3 (c), a reactor case 11 made of a strength member is provided on the rear outer wall surface of the PCU 1 with respect to the vehicle EV, that is, on the isolation side of the passenger compartment and the vehicle compartment separating the motor compartment. Yes. Reactor case 11 includes a reactor receiving portion 11a and a reactor cover 11b, and stores reactor R therein. Reactor case 11 is a mold made of aluminum having good heat conduction in order to improve heat dissipation because reactor R has a high surface due to Joule heat caused by coil winding resistance and Joule heat caused by eddy current generated in the iron core. It consists of parts.
[0022]
Next, the high voltage terminal block 6 will be described.
As shown in FIG. 2, the high-voltage terminal block 6 is disposed on the back side of the region guarded by the strength member 7, that is, the position facing the strength member 7 with the case of the high-pressure box 10 interposed therebetween. FIG.3 (d) is sectional drawing of the AA shown in (b).
As shown in FIG. 3 (d), the strength member 7 is, for example, a reactor case 11 storing a reactor R, but the high-voltage terminal block 6 is a high-pressure box at a position opposite to the reactor case 11. A stay 5 is provided on the inner wall surface of 10, and a high voltage terminal block 6 is provided on the stay 5.
The reactor case 11 combining the reactor receiving portion 11a and the reactor cover 11b is robust and can sufficiently guard the high-voltage terminal block 6 with the strength member 7 against an impact at the time of collision.
Further, as shown in FIG. 3A, insulating partition walls 6a, 6a,... Are provided between the high-voltage terminals. By providing at least between the high voltage box 10 and the terminal closest thereto, an insulation distance can be secured even when the high voltage box 10 is deformed.
[0023]
Therefore, for example, even if the vehicle collides from the front or the rear and damage is applied to the high pressure box of the PCU 1, the high pressure disposed in the region guarded by the reactor case 11 that is the strength member 4 is provided. The terminal block 6 is not deformed or damaged because the strength member 4 firmly protects the high-voltage terminal block 6 in the event of a collision, and there is no risk of short-circuiting due to the penetration of other parts, improving reliability and ensuring quality assurance. Can do.
[0024]
The present invention can be variously modified and changed within the scope of the technical idea, and the present invention naturally extends to the modified and changed invention. For example, although the embodiment in which the present invention is applied to a fuel cell electric vehicle has been described, the present invention can also be applied to a normal electric vehicle or a hybrid vehicle equipped with an engine, a travel motor, and a battery. In that case, the FC cable connected to the fuel cell 2 is omitted, and the high voltage cable is composed of a MOT cable and a CAPA cable.
In addition, since the strength member 7 is disposed on the partition side with the vehicle interior, the high-voltage terminal block 6 is also on the partition side with the vehicle interior, but is not limited to the partition side with the vehicle interior, and can be either front, back, left, or right Good.
The high-voltage terminal block 6 is placed on the stay 5 formed integrally with the high-voltage box 10. However, the stay 5 may be a separate part or the stay 5 may be omitted.
Furthermore, the strength member 7 may be replaced with another component instead of the reactor case 11, or the plate thickness of the high-pressure box 10 may be reinforced thickly instead of another component.
In addition, as a representative example of an electric vehicle as an embodiment of the present invention, an example of a vehicle equipped with a fuel cell has been described, but the power control unit of the present invention is not limited to that for a vehicle equipped with a fuel cell, Widely applicable.
For example, a hybrid vehicle and a solar car equipped with a battery can also be applied to a solar car having a solar panel and a battery or a general electric vehicle.
Furthermore, a high-voltage terminal block having such an arrangement structure is also within the scope of the present invention.
[0025]
【The invention's effect】
According to the first aspect of the invention, the arrangement of the high voltage terminal block in the high voltage box of the electric vehicle power control unit is arranged in front of the region of the strength member where the high voltage box is most deformed. There is no risk of other parts penetrating or short-circuiting, and an insulating cover is not required to ensure insulation. In addition to improving reliability, quality assurance can be ensured. Reduction, realization of a miniaturized design, and the like.
[Brief description of the drawings]
FIG. 1 is a schematic view seen through from the side of a vehicle equipped with a PCU according to an embodiment of the present invention and a conventional example.
FIG. 2 is a block diagram showing a connection state of a high voltage cable and a position of a high voltage terminal in the vehicle of FIG.
FIG. 3 is a schematic diagram of a three-sided view showing the arrangement of a high-voltage box and a traveling motor, (a) is an upper surface showing a state where a lid is removed from the front of the vehicle as viewed from the upper surface of a PCU disposed in the motor chamber FIG. 5B is a front view of the PCU and the traveling motor as viewed from the front, and FIG. 5C is a right side view with respect to FIG. (D) is a cross-sectional view taken along line AA shown in (b).
FIG. 4 is a block diagram showing a connection state of a high voltage cable and a position of a high voltage terminal in a conventional vehicle.
FIG. 5 is a three-sided view showing the arrangement of a conventional high-voltage box and a traveling motor, (a) is a top view showing the configuration from the top surface by removing the lid of the PCU arranged in the motor chamber from the front of the vehicle; (B) is a front view of the PCU and the traveling motor, and (c) is a right side view with respect to (a).
[Explanation of symbols]
1 ... PCU (Power control unit for electric vehicles)
2 ... Fuel cell 3 ... Capacitor 4 ... Traveling motor 5 ... Stay 6 ... High voltage terminal block 6a ... Insulating partition 7 ... Strength member 8 ... VCU (Voltage Control Unit)
9 ... INV (Inverter)
DESCRIPTION OF SYMBOLS 10 ... High pressure box 10a ... Cover 11 ... Reactor case 11a ... Reactor receiving part 11b ... Reactor cover 13 ... Connector case 13a ... Partition (beam member)
R ... Reactor EV ... Electric vehicle MOT ... Three-phase motor

Claims (1)

A power control unit for an electric vehicle voltage control unit is built to perform voltage adjustment between the inverter and the power supply for driving the motor driven in the high-pressure box,
A high-voltage terminal block that connects cables,
And a strength member fixed to the outer surface of the side wall of the high-pressure box,
Providing the high voltage terminal block close to the inner surface of the high voltage box facing the strength member across the side wall,
A power control unit for an electric vehicle, wherein a part of the strength member is provided so as to extend inside the side wall, and the high-voltage terminal block is disposed above the part of the strength member.

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