JP7230852B2 - POWER CONVERTER AND METHOD FOR MANUFACTURING POWER CONVERTER - Google Patents

Description

The disclosure in this specification relates to a power converter that converts direct current to alternating current or converts the magnitude of voltage, and a method of manufacturing the power converter.

Patent Literature 1 describes a power converter including an input terminal block, a capacitor, a semiconductor module, a case, and the like.

The input terminal block has a connector portion that is connected to the external battery and is electrically connected to the capacitor. The semiconductor module converts the power input through the input terminal block from direct current to alternating current. A capacitor smoothes the voltage ripple of the power. The case accommodates the input terminal block, the capacitor and the semiconductor module, and has an opening into which the connector section is inserted. Further, the case is divided into a first case in which the opening is formed and a second case fastened to the first case.

Japanese Patent No. 6308091

Now, in a structure in which a semiconductor module is fixed to the first case, a capacitor is fixed to the second case, and then both cases are fastened and combined, when an input terminal block is attached to the capacitor to form a unit, the following results are obtained. issues arise. That is, with the unitization, the input terminal block is held in the second case together with the capacitor. Then, it becomes necessary to insert the connector portion held by the second case into the opening of the first case.

However, the semiconductor module is fixed to the first case and the capacitor is fixed to the second case. Therefore, when the connector portion is set and inserted into the opening, the semiconductor module and the capacitor interfere with each other, and there arises a concern that the setting cannot be performed.

If this type of input terminal block is composed of two parts, the first part having the connector portion and the second part electrically connected to the capacitor, the first part is held by the first case and the second part is held by the first case. A component can be held in the second case. As a result, the first connector section can be set in the opening without causing the interference. However, in this case, the number of parts of the input terminal block increases.

One object of the disclosure is to provide a power conversion device and a method of manufacturing the same that can reduce the number of parts of a terminal block.

To achieve the above object, one disclosed means is
a terminal block (70, 80) electrically connected to an external battery (2) or motor (3);
a first electrical component (40) and a second electrical component (50) for converting the power supplied from the battery from direct current to alternating current or for converting the magnitude of the voltage of the supplied power;
a case (10) housing the first electrical component, the second electrical component and the terminal block;
with
the case is
a first case (11) having an opening (11c) into which a part of the terminal block is inserted and arranged, and to which the first electric component is fixed;
a second case (12) combined with the first case and fixed with a second electrical component in a state in which the terminal block is electrically connected;
has
The first electrical component and the second electrical component have opposing portions (43a, 51a) that are aligned in the insertion direction in which a part of the terminal block is inserted into the opening and face each other,
The facing portion of the first electric component is the first facing portion (43a), the facing portion of the second electric component is the second facing portion (51a),
The shortest separation distance (L1) between the first facing portion and the second facing portion in the insertion direction is greater than the insertion amount (L2) of the terminal block inserted into the opening from the inside of the case.

According to the above power converter, the shortest separation distance between the two electrical components in the insertion direction is greater than the amount of insertion into the opening of the terminal block. Therefore, it is possible to prevent the two electrical components from interfering with each other when a part of the terminal block is set in the opening and is about to be inserted. Therefore, it is possible to insert a portion of the terminal block into the opening while eliminating the need to separate the terminal block and hold it in each of the two cases. That is, the number of parts of the terminal block can be reduced.

To achieve the above object, one disclosed means is
a terminal block (70, 80) electrically connected to an external battery (2) or motor (3);
a first electrical component (40) and a second electrical component (50) for converting the power supplied from the battery from direct current to alternating current or for converting the magnitude of the voltage of the supplied power;
A case (10) for housing the first electrical component, the second electrical component and the terminal block,
the case is
a first case (11) having an opening (11c) into which a part of the terminal block is inserted and arranged, and to which the first electric component is fixed;
a second case (12) fastened to the first case and fixed with a second electrical component in a state in which the terminal block is electrically connected;
has
The first electrical component and the second electrical component have opposing portions (43a, 51a) that are aligned in the insertion direction in which a part of the terminal block is inserted into the opening and face each other,
The facing portion of the first electric component is the first facing portion (43a), the facing portion of the second electric component is the second facing portion (51a),
A method for manufacturing a power conversion device, wherein the shortest separation distance (L1) between the first opposing portion and the second opposing portion in the insertion direction is greater than the insertion amount (L2) for inserting the terminal block into the opening from the inside of the case. hand,
a first fixing step (S12) of fixing the first electrical component to the first case;
a second fixing step (S22) of electrically connecting the second electrical component to the terminal block and fixing the second electrical component to the second case;
After the first fixing step and the second fixing step, the first case and the second case are relatively displaced in the insertion direction from the fastening position so that the entire terminal block exists outside the opening. a pre-arrangement step (S30) to
After the pre-arrangement step, an insertion step (S40) of inserting a portion of the terminal block into the opening by relatively moving the first case and the second case in the insertion direction;
After the inserting step, a case fastening step (S50) of fastening the first case and the second case together;
and a method for manufacturing a power conversion device.

In the power conversion device to which the above manufacturing method is applied, the shortest separation distance between the two electrical components in the insertion direction is larger than the amount of insertion into the opening of the terminal block. Therefore, it is possible to prevent the first electrical component and the second electrical component from interfering with each other during the pre-arrangement process. Therefore, it is possible to insert a portion of the terminal block into the opening while eliminating the need to separate the terminal block and hold it in each of the two cases. That is, the number of parts of the terminal block can be reduced.

It should be noted that the reference numbers in parentheses above merely indicate an example of correspondence with specific configurations in the embodiments described later, and do not limit the technical scope in any way.

It is a figure which shows a circuit structure about the power converter device which concerns on 1st Embodiment. BRIEF DESCRIPTION OF THE DRAWINGS It is sectional drawing of the power converter device which concerns on 1st Embodiment. 4 is a perspective view showing a state in which the first capacitor unit, the second capacitor unit and the input terminal block are connected to each other in the first embodiment; FIG. 3 is an exploded view of the power converter shown in FIG. 2; FIG. 4 is a flow chart showing the manufacturing process procedure of the method for manufacturing the power conversion device according to the first embodiment. It is a figure which shows the state in the pre-arrangement process of the power converter device which concerns on 1st Embodiment. It is a figure which shows the state in the insertion process of the power converter device which concerns on 1st Embodiment.

A number of embodiments will be described with reference to the drawings. In several embodiments, functionally and/or structurally corresponding parts are provided with the same reference numerals. In the following description, the vertical direction of the electric power converter mounted on the vehicle is referred to as the z-direction, and one direction orthogonal to the z-direction is referred to as the x-direction. A direction perpendicular to both the z-direction and the x-direction is referred to as the y-direction. Note that the direction of the arrow indicating the z direction in the drawing is the upper side in the vehicle-mounted state.

(First embodiment)
First, based on FIG. 1, the outline of the electric circuit formed by the power conversion device 1 will be described.

A power conversion device 1 according to this embodiment is mounted in a vehicle such as an electric vehicle or a hybrid vehicle, for example. The power conversion device 1 converts a DC voltage supplied from a battery 2 (DC power supply) mounted on a vehicle into a three-phase AC and outputs it to a three-phase AC motor 3 (vehicle motor). The motor 3 functions as a travel drive source for the vehicle. The power converter 1 can also convert the electric power generated by the motor 3 into direct current and charge the battery 2 . The power conversion device 1 is capable of bidirectional power conversion.

As shown in FIG. 1, the power converter 1 includes a control board 30, a semiconductor module 21, a capacitor 50C, a reactor 60L, an input terminal block 70 and an output terminal block 80.

The semiconductor module 21 has a structure including a switching element 21i, a terminal connected to the switching element 21i, and a molding material. The molding material is made of resin for molding the switching element 21i. The terminals include a P terminal, an N terminal, and a signal terminal 21s, which will be described later. In the example shown in FIG. 1, one semiconductor module 21 has two switching elements 21i and forms one upper and lower arm circuit.

A plurality of semiconductor modules 21 are provided, one of which is connected to the reactor 60L. The semiconductor module 21 connected to the reactor 60L is a DC-DC converter and functions as a converter circuit that boosts the DC voltage. The plurality of other semiconductor modules 21 are DC-AC converters, and function as inverter circuits that convert the input DC power into three-phase AC power of a predetermined frequency and output it to the motor 3 . This inverter circuit also has a function of converting AC power generated by the motor 3 into DC power.

A semiconductor module 6 as an inverter circuit is provided for each of the three phases of the motor 3 .

An n-channel insulated gate bipolar transistor (IGBT) is employed as the switching element 21i. A collector electrode of the IGBT on the upper arm is connected to the high-potential power line Hi. The emitter electrode of the IGBT on the lower arm is connected to the low potential power line Lo. The emitter electrodes of the IGBTs on the upper arms and the collector electrodes of the IGBTs on the lower arms 5L and 6L are connected to each other.

The capacitor 50C is connected between the high potential power line Hi and the low potential power line Lo. Capacitor 50C is connected in parallel with semiconductor module 21 . Capacitor 50C smoothes the DC current boosted by the converter circuit. Capacitor 50C accumulates the charge of the boosted DC voltage.

Reactor 60L boosts the voltage of battery 2 in accordance with the switching operation of semiconductor module 21 functioning as a converter circuit.

The control board 30 has a control section and a drive circuit section (driver). The control unit generates a drive command for operating the switching element 21i based on a torque request input from the host ECU and signals detected by various sensors. The control unit includes a microcomputer and outputs a PWM signal as a drive command. The driver controls the on/off operation of the switching element 21i according to the drive command output from the control section.

Specific examples of the various sensors described above include the current sensor 81, voltage sensor, rotation angle sensor, and the like. The current sensor 81 detects a phase current flowing through each phase winding of the motor 3 . The rotation angle sensor detects the rotation angle of the rotor of the motor 3 .

Next, various units and parts constituting the power conversion device 1 will be described with reference to FIGS. 2 to 4. FIG.

The power converter 1 includes a case 10 , a semiconductor unit 20 , a control board 30 , a first capacitor unit 40 , a second capacitor unit 50 , a reactor unit 60 , an input terminal block 70 and an output terminal block 80 . 2 to 4, illustration of the output terminal block 80 is omitted.

The case 10 is made of metal, and is formed by die casting using an aluminum-based material, for example. Case 10 accommodates semiconductor unit 20 , control board 30 , first capacitor unit 40 , second capacitor unit 50 , reactor unit 60 , input terminal block 70 and output terminal block 80 inside.

The case 10 is divided into two, a first case 11 and a second case 12 . The first case 11 and the second case 12 are fastened with bolts B1. The dividing plane between the first case 11 and the second case 12 is a plane perpendicular to the z-direction. Both cases are formed with flange surfaces 11f and 12f that abut against each other, and these flange surfaces 11f and 12f correspond to the dividing surfaces. The flange surfaces 11f and 12f have a flat shape extending perpendicularly to the z-direction, and the fastening direction of the bolt B1 is the z-direction.

The opening 11b formed on the lower side of the first case 11 and the opening 12b formed on the upper side of the second case 12 communicate with each other by the above fastening. The flange surfaces 11f and 12f have a shape extending annularly around the z-direction so as to surround these openings 11b and 12b.

The first case 11 is formed with an opening 11a that opens upward. The opening 11a is covered with a first cover 13 fastened to the first case 11 with bolts B2. The second case 12 is formed with an opening 12a that opens downward. The opening 12a is covered with a second cover 14 fastened to the second case 12 with bolts B3.

Further, the first case 11 is formed with a connector opening 11c and a piping opening 11d. An input connector portion 73, which will be described later, is inserted into the connector opening 11c, and a refrigerant pipe 23, which will be described later, is inserted into the piping opening 11d. The connector opening 11c opens toward one side in the x direction. The piping opening 11d opens toward the other side in the x direction. A tubular portion 110 forming the connector opening 11c of the first case 11 has a tubular shape extending in the x direction.

The semiconductor unit 20 has the semiconductor module 21, the cooler, the elastic member 24, and the base member 25, which were previously described with reference to FIG.

The cooler cools the semiconductor module 21, has a heat exchange section 22 and a refrigerant pipe 23, and forms a part of a circulation path for circulating the liquid refrigerant. The refrigerant pipes 23 include an inflow refrigerant pipe into which the refrigerant flows from the outside of the semiconductor unit 20 and an outflow refrigerant pipe into which the refrigerant flows out of the semiconductor unit 20 .

The heat exchange portion 22 communicates with refrigerant pipes 23 for inflow and outflow. The heat exchange unit 22 contacts the semiconductor module 21 via an insulator having good thermal conductivity, and cools the semiconductor module 21 whose temperature rises due to the heat generated by the switching element 21i.

A plurality of semiconductor modules 21 are stacked and arranged side by side in the x direction. The heat exchange section 22 is arranged between the adjacent semiconductor modules 21 . In other words, the plurality of heat exchange units 22 and the semiconductor modules 21 are alternately stacked. An elastic force generated by elastic deformation of the elastic member 24 is applied to the laminated body composed of the plurality of semiconductor modules 21 and the heat exchange section 22 via the base member 25 . Due to this elastic force, the semiconductor module 21 and the heat exchange section 22 are pressed against each other and are in close contact with each other.

As described above, the terminals of the semiconductor module 21 include the P terminal, the N terminal, and the signal terminal 21s (not shown). The P terminal is connected to the emitter electrode of the switching element 21i forming the upper arm. One end of a first P bus bar 42P, which will be described later, is connected to the P terminal, and the other end of the first P bus bar 42P is connected to the high potential side electrode of the capacitor 50C. That is, the P terminal has the same potential as the high potential power line Hi.

The N terminal is connected to the collector electrode of the switching element 21i forming the lower arm. One end of the first N bus bar 42N is connected to the N terminal, and the low potential side electrode of the capacitor 50C is connected to the other end of the first N bus bar 42N. That is, the N terminal has the same potential as the low potential power line Lo.

The signal terminal 21s is connected to the gate electrode of the switching element 21i. The signal terminal 21 s is mounted (for example, inserted) on the control board 30 . The signal terminal 21s extends upward from the molding material. Note that the P terminal and the N terminal extend downward from the molding material.

The control board 30 is arranged above the semiconductor unit 20 in the z-direction, and is arranged at a position facing the opening 11 a of the first case 11 . The control board 30 has a connector 31 connected to an external ECU. A portion of the connector 31 is exposed through an opening (not shown) formed in the first cover 13 . The control board 30 acquires various kinds of vehicle information and outside information from an external ECU through the connector 31 .

Further, the control board 30 has a processor that executes arithmetic processing according to a predetermined program, and a memory that stores the above-described programs. For example, these processors and memories are packaged as a microcomputer (microcomputer). The control board 30 has a drive circuit that outputs a drive signal to the switching element 21i. The microcomputer commands the operation of the semiconductor module 21 based on various information acquired through the connector 31 . Based on the command, the drive circuit outputs a drive signal.

Here, the capacitance required for the capacitor 50C shown in FIG. 1 is extremely large. Therefore, in practice, a plurality of capacitors 50C are connected in parallel to meet the required capacitance.

The plurality of capacitors 50C are arranged separately in the first capacitor unit 40 and the second capacitor unit 50 . Note that the number of capacitors 50C included in first capacitor unit 40 is set larger than the number of capacitors 50C included in second capacitor unit 50. FIG.

The first capacitor unit 40 has a first capacitor case 41 , a plurality of capacitors 50</b>C, a first P busbar 42</b>P, a first N busbar 42</b>N and an electrical insulator 43 . A plurality of capacitors 50</b>C are housed inside the first capacitor case 41 . The inside of the first capacitor case 41 is filled with a resin material (not shown) that covers the entire capacitor 50C.

The high potential side electrode of the capacitor 50C and the emitter electrode of the switching element 21i are connected to the first P bus bar 42P. The low potential side electrode of the capacitor 50C and the collector electrode of the switching element 21i are connected to the first N bus bar 42N.

The first P bus bar 42P and the first N bus bar 42N are plate-shaped and have plate surfaces facing each other (opposing plate surfaces). A plate-like electrical insulator 43 is arranged between these opposed plate surfaces. The electrical insulator 43 is made of resin having electrical insulation.

The second capacitor unit 50 has a second capacitor case 51, a plurality of capacitors 50C, a second P bus bar 52P and a second N bus bar 52N. A plurality of capacitors 50</b>C are housed inside the second capacitor case 51 . The inside of the second capacitor case 51 is filled with a resin material (not shown) that covers the entire capacitor 50C. The first P bus bar 42P and the first N bus bar 42N of the first capacitor unit 40 are connected to one ends of the second P bus bar 52P and the second N bus bar 52N.

A film capacitor in the form of a wound film is used as the capacitor 50C. The size and number of the capacitors 50C are adjusted by adjusting the width and number of turns of the film and the number of film capacitors used. By adjusting the arrangement of the plurality of capacitors 50C, the desired shapes of the first capacitor case 41 and the second capacitor case 51 are realized.

All the film capacitors of the first capacitor unit 40 are arranged so that the winding centerline is oriented in the y direction. All the film capacitors of the second capacitor unit 50 are arranged so that the winding center line faces the z-direction. In short, the winding center line of the first capacitor unit 40 and the winding center line of the second capacitor unit 50 are orthogonal.

In addition, each bus bar which the 1st capacitor|condenser unit 40 and the 2nd capacitor|condenser unit 50 have may be distinguished and called as follows. That is, the first P busbars 42P and 52P are called the first P busbar 42P and the second P busbar 52P, respectively. Also, the first N bus bars 42N and 52N are referred to as the first N bus bar 42N and the second N bus bar 52N, respectively.

Reactor unit 60 has a reactor case 61 and a reactor 60L. Reactor 60L is housed inside reactor case 61 . The reactor unit 60 is arranged below the semiconductor unit 20 in the z direction, and is arranged at a position facing the opening 12 a of the second case 12 . Reactor unit 60 is also arranged below first capacitor unit 40 and second capacitor unit 50 in the z direction. One end of the reactor 60L is connected to the semiconductor module 21 via a busbar (not shown). The other end of reactor 60L is connected to the high potential side of battery 2 via input terminal block 70 .

The input terminal block 70 has a main body case 71 , an input P bus bar 72 P, an input N bus bar 72 N and an input connector section 73 . The body case 71 is made of an electrically insulating resin, and holds the input P bus bar 72P, the input N bus bar 72N, and the input connector section 73. As shown in FIG.

The input connector portion 73 has a connector fitting portion and connector terminals. The connector fitting portion is made of resin integrally formed with the main body case 71 and fits with the fitting portion of the external connector. This external connector is attached to the tip of a cable connected to the battery 2 . The connector terminals are arranged in the connector fitting portion, and are electrically connected to the terminals of the external connector as a result of the fitting.

The input P bus bar 72P is connected to the reactor 60L, and the input N bus bar 72N is connected to the second N bus bar 52N. Although the power conversion device 1 according to the present embodiment includes the reactor unit 60, the reactor unit 60 may be omitted. In that case, the input P bus bar 72P will be connected to the second P bus bar 52P.

The output terminal block 80 has a current sensor 81, and a body case, an output bus bar, and an output connector section (not shown). The body case is made of an electrically insulating resin, and holds the output bus bar and the output connector. The output connector portion is connector-connected to a cable connected to the motor 3 .

The x-, y-, and z-directions mentioned above are defined as follows. The z-direction is a direction perpendicular to the board surface of the control board 30 . The x direction is the direction in which the semiconductor unit 20 and the second capacitor unit 50 are arranged along the plate surface. The y direction is the direction perpendicular to the z and x directions.

Now, the first capacitor unit 40 corresponds to a “first electric component” fixed to the first case 11 . The second capacitor unit 50 corresponds to a “second electrical component” fixed to the second case 12 while the input terminal block 70 is electrically connected. Therefore, when the connector portion of the input connector portion 73 is set to face the connector opening portion 11c and is about to be inserted, the first capacitor unit 40 and the second capacitor unit 50 do not interfere with each other. The following structure is adopted in the embodiment.

In the following description, the direction (x direction) in which the input connector portion 73, which is a part of the input terminal block 70, is inserted into the connector opening 11c is called the insertion direction. The first capacitor unit 40 and the second capacitor unit 50 have opposing portions 43a and 51a that are aligned in the insertion direction and face each other.

Specifically, the first facing portion 43 a that is the facing portion of the first capacitor unit 40 is the portion of the electrical insulator 43 that faces the second capacitor case 51 . A second facing portion 51 a , which is a facing portion of the second capacitor unit 50 , is a portion of the second capacitor case 51 that faces the electrical insulator 43 . These facing portions 43a and 51a have a flat shape extending perpendicularly to the insertion direction.

The shortest separation distance L1 (see FIG. 2) between the first facing portion 43a and the second facing portion 51a in the insertion direction is greater than the insertion distance L2 (see FIG. 2) for inserting the input connector portion 73 into the connector opening 11c. big.

Next, a method for manufacturing the power converter 1 will be described with reference to FIGS. 5 and 6. FIG.

First, the work in steps S11 and S12 in FIG. 5 and the work in steps S21 and S22 are executed separately.

In step S11 (first assembly step), semiconductor unit 20, control board 30 and first capacitor unit 40 are manufactured. Thereafter, in step S11, a first assembly U1 (see FIG. 6) is manufactured in which the semiconductor unit 20, the control board 30 and the first capacitor unit 40 are connected to each other.

Specifically, the semiconductor unit 20 is manufactured by assembling the semiconductor module 21, the heat exchange section 22 and the refrigerant pipe 23 together. Also, the control board 30 is manufactured by mounting the connector 31, the microcomputer, etc. on the board. A capacitor 50</b>C to which the first P bus bar 42</b>P and the first N bus bar 42</b>N are connected is arranged in the first capacitor case 41 . After that, the first capacitor case 41 is filled with a resin material, and the electric insulator 43 is arranged between both bus bars to manufacture the first capacitor unit 40 .

After that, the first P bus bar 42P and the first N bus bar 42N are connected (eg, welded) to the P terminal and the N terminal of the semiconductor unit 20, respectively. Also, the signal terminal 21s of the semiconductor unit 20 is connected to the control board 30 (for example, insertion mounting). As described above, the above-described first assembly U1 is manufactured.

In subsequent step S<b>12 (first fixing step), the first assembly U<b>1 manufactured in step S<b>11 is fixed to the first case 11 . Specifically, the first capacitor unit 40 is fixed to the first case 11 by fixing the bracket 41a (see FIG. 3) provided on the first capacitor unit 40 to the first case 11 with bolts.

In step S21 (second assembly step), the second capacitor unit 50 and the input terminal block 70 are manufactured. Thereafter, in step S21, the second assembly U2 (see FIG. 6) is manufactured in which the second capacitor unit 50 and the input terminal block 70 are connected to each other.

Specifically, the capacitor 50</b>C to which the second P bus bar 52</b>P and the second N bus bar 52</b>N are connected is arranged in the second capacitor case 51 . Thereafter, the second capacitor case 51 is filled with a resin material to manufacture the second capacitor unit 50 . In addition, the input terminal block 70 is manufactured by providing the input P bus bar 72P, the input N bus bar 72N and the input connector portion 73 in the body case 71 .

After that, the second N bus bar 52N and the input N bus bar 72N are connected to each other. This connection may be bolted or welded. As described above, the above-described second assembly U2 is manufactured.

In the following step S22 (second fixing step), the second assembly U2 manufactured in step S21 is fixed to the second case 12. As shown in FIG. Specifically, the second capacitor unit 50 is fixed to the second case 12 by fixing a bracket (not shown) provided on the second capacitor unit 50 to the second case 12 with bolts.

In step S30 (pre-arrangement step) executed after steps S12 and S22, the first case 11 is moved to the first position so that the entire input connector portion 73 (input terminal block 70) exists outside the connector opening portion 11c. 2 Temporarily place it on the case 12 (see FIG. 7). The first case 11 in the temporarily placed state is at a position relatively displaced in the insertion direction from the position where it can be fastened with the second case 12 . For example, the first assembly U1 is brought closer to the second assembly U2 in the z-direction as shown in FIG. place it temporarily.

In this temporary placement step, the tubular portion 110 of the first case 11 and the input connector portion 73 are separated from each other in the x direction so that the tubular portion 110 of the first case 11 does not interfere with the input connector portion 73 . However, if this separation distance is excessively large, the first facing portion 43a interferes with the second facing portion 51a. Therefore, the tubular portion 110 and the input connector portion 73 are spaced apart in the x direction to such an extent that the first facing portion 43a does not interfere with the second facing portion 51a. As described above, since the shortest separation distance L1 is set larger than the insertion amount L2, it is possible to realize the positional relationship without interference as described above.

In step S40 (insertion step) executed thereafter, the first case 11 and the second case 12 are relatively moved in the insertion direction. That is, the input connector portion 73 is inserted into the connector opening portion 11c by the insertion amount L2. Then, the first case 11 is moved to a proper position where it can be fastened with the second case 12 . In this movement, the flange surface 11f of the first case 11 is slid while being in contact with the flange surface 12f of the second case 12. As shown in FIG. At the normal position, the shortest separation distance L1 is larger than the insertion amount L2.

In step S50 (case fastening step) that is executed thereafter, the first case 11 and the second case 12 in the normal positions are fastened together with the bolts B1.

In step S60 (busbar fastening step) executed thereafter, the first assembly U1 and the second assembly U2 are electrically connected. Specifically, the first P bus bar 42P is connected to the second P bus bar 52P. Also, the first N bus bar 42N is connected to the second N bus bar 52N. These connections may be bolted or welded. Further, as described in step S30, the first assembled body U1 is temporarily placed from above the second assembled body U2. Therefore, the first P bus bar 42P is arranged so as to overlap the upper side of the second P bus bar 52P. Moreover, the 1st N bus bar 42N is arrange|positioned so that it may overlap on the upper side of the 2nd N bus bar 52N.

In step S70 (cover fastening step) executed thereafter, the first cover 13 is fastened to the first case 11 with the bolts B2. Also, the second cover 14 is fastened to the second case 12 with bolts B3. Note that the process of step S70 may be performed in steps S12 and S22.

The effect of having the above configuration will be described below.

As described above, in the power converter 1 , the first capacitor unit 40 is fixed to the first case 11 . The second capacitor unit 50 is fixed to the second case 12 with the input terminal block 70 electrically connected thereto. In addition, the shortest separation distance L1 in the insertion direction between the first capacitor unit 40 and the second capacitor unit 50 is greater than the insertion amount L2 for inserting the input connector portion 73 into the connector opening portion 11c.

Therefore, it is possible to prevent the first capacitor unit 40 and the second capacitor unit 50 from interfering with each other when the input connector portion 73 is set at a position facing the connector opening 11c and is about to be inserted. Therefore, according to the present embodiment, the input connector portion 73 can be inserted into the connector opening portion 11c while eliminating the need to divide the input terminal block 70 and hold it in each of the first case 11 and the second case 12. structure. That is, the number of parts of the input terminal block 70 can be reduced.

Furthermore, in this embodiment, the power conversion device 1 in which the shortest separation distance L1 is set to be larger than the insertion amount L2 is manufactured by the following manufacturing method. In this manufacturing method, first, both capacitor units 40 and 50 are fixed to both cases 11 and 12, respectively. After that, both cases 11 and 12 are temporarily placed while being relatively displaced from their normal positions in the insertion direction (pre-arrangement step). After that, the input connector portion 73 is inserted into the connector opening portion 11c by relatively moving both cases 11 and 12 in the insertion direction. After that, both cases 11 and 12 are fastened together.

According to this, it is possible to prevent both capacitor units 40 and 50 from interfering with each other during the pre-arrangement process. Therefore, it is possible to insert a part of the input terminal block 70 (the input connector portion 73) into the connector opening 11c while eliminating the need to divide the input terminal block 70 and hold it in each of the cases 11 and 12. .

Furthermore, in this embodiment, the first capacitor unit 40 as the first electric component has a first P bus bar 42P and a first N bus bar 42N. These bus bars generate heat when energized. Also, the second capacitor unit 50 as the second electrical component has a capacitor 50C. Capacitor 50C is generally an electrical component that is easily damaged by heat. That is, the first electrical component has a heat generating portion, and the second electrical component has an electrical component that is easily damaged by heat.

In view of this point, in the present embodiment, the first facing portion 43a that specifies the shortest separation distance L1 described above is the electrical insulator 43 that is sandwiched between the busbars that serve as heat generating portions. Also, the second facing portion 51a that specifies the shortest distance L1 is an electrical component that is easily damaged by heat. Therefore, by making the shortest separation distance L1 larger than the insertion amount L2, the separation distance between the heat-generating part and the electric component is increased. Therefore, the heat dissipation of the electrical component can be improved. In other words, the shortest separation distance L1 can function not only as a gap for offset assembly, but also as a heat dissipation gap for the heat-generating part, so that the power conversion device 1 can be miniaturized.

(Other embodiments)
The disclosure in this specification, drawings, etc. is not limited to the illustrated embodiments. The disclosure encompasses the illustrated embodiments and variations thereon by those skilled in the art. For example, the disclosure is not limited to the combinations of parts and/or elements shown in the embodiments. The disclosure can be implemented in various combinations. The disclosure can have additional parts that can be added to the embodiments. The disclosure encompasses omitting parts and/or elements of the embodiments. The disclosure encompasses permutations or combinations of parts and/or elements between one embodiment and another.

In the first embodiment, the first opposing portion 43a is part of the electrical insulator 43, but may be part of the first P bus bar 42P or the first N bus bar 42N. Further, the first facing portion 43a is not limited to a heat generating portion that generates heat when energized, and may be a part of the first capacitor case 41, for example.

Although the second facing portion 51a is a part of the second capacitor case 51 in the first embodiment, it may be a heat-generating portion that generates heat when energized. Specific examples of the heat-generating portion include part of the second P bus bar 52P and the second N bus bar 52N.

In the first embodiment described above, the first capacitor unit 40 having the capacitor 50C is the first electrical component. On the other hand, for example, the semiconductor unit 20 or the reactor unit 60 may be the first electric component. Similarly, the semiconductor unit 20 and the reactor unit 60 may be the second electrical component. Moreover, the power conversion device 1 may include a DCDC converter that converts the magnitude of the voltage of the DC power. In that case, the first electrical component or the second electrical component may be a DCDC converter.

In the first embodiment, the input terminal block 70 is used as the terminal block connected to and held by the second electrical component, but the output terminal block 80 may be used.

In the above-described first embodiment, the plurality of semiconductor modules 21 are stacked and arranged side by side in the y direction. On the other hand, the plurality of semiconductor modules 21 may be stacked side by side in the x direction. In short, the stacking direction of the semiconductor modules 21 and the direction in which the capacitor units and the terminal units are arranged may be orthogonal or parallel.

The power converter 1 according to the first embodiment includes an inverter circuit for converting the power supplied from the battery 2 from direct current to alternating current, and a converter circuit for converting the magnitude of the voltage of the supplied power. On the other hand, the power conversion device may have a configuration in which either one of the inverter circuit and the converter circuit is eliminated and the other is provided.

10 Case 11 First Case 11c Connector Opening (Opening) 12 Second Case 2 Battery 3 Motor 40 First Electric Component 42N N Busbar 42P P Busbar 43 Electrical Insulator 43a Second 1 facing part 50 second electric component 50C capacitor 51a second facing part 70 input terminal block (terminal block) 80 output terminal block (terminal block) L1 shortest distance L2 insertion amount 42N N bus bar 42P P bus bar, S12 first fixing step, S22 second fixing step, S30 pre-arrangement step, S40 insertion step, S50 case fastening step.

Claims (5)

a terminal block (70, 80) electrically connected to an external battery (2) or motor (3);
a first electrical component (40) and a second electrical component (50) for converting the power supplied from the battery from direct current to alternating current or for converting the magnitude of the voltage of the supplied power;
a case (10) housing the first electrical component, the second electrical component and the terminal block;
with
Said case is
a first case (11) having an opening (11c) into which a part of the terminal block is inserted and arranged, and to which the first electrical component is fixed;
a second case (12) combined with the first case and fixed with the second electrical component in a state where the terminal block is electrically connected;
has
The first electrical component and the second electrical component have opposing portions (43a, 51a) that are aligned in an insertion direction in which a portion of the terminal block is inserted into the opening and face each other,
The facing portion of the first electrical component is defined as a first facing portion (43a), and the facing portion of the second electrical component is defined as a second facing portion (51a),
The shortest separation distance (L1) between the first facing portion and the second facing portion in the insertion direction is greater than an insertion amount (L2) for inserting the terminal block into the opening from the inside of the case (L2) for power conversion. Device. 2. The power converter according to claim 1, wherein one of said first facing portion and said second facing portion is a heat generating portion that generates heat when energized. 3. The power converter according to claim 2, wherein, of said first electrical component and said second electrical component, the electrical component having the other of said first facing portion and said second facing portion includes a capacitor (50C). the second electrical component includes a capacitor (50C);
The first electrical component is
a P bus bar (42P) electrically connected to the high potential side of the capacitor;
an N busbar (42N) electrically connected to the low potential side of the capacitor;
an electrical insulator (43) disposed between said P busbar and said N busbar;
has
2. The power converter according to claim 1, wherein said first facing portion is one of said P bus bar, said N bus bar and said electrical insulator. a terminal block (70, 80) electrically connected to an external battery (2) or motor (3);
a first electrical component (40) and a second electrical component (50) for converting the power supplied from the battery from direct current to alternating current or for converting the magnitude of the voltage of the supplied power;
A case (10) that houses the first electric component, the second electric component and the terminal block,
Said case is
a first case (11) having an opening (11c) into which a part of the terminal block is inserted and arranged, and to which the first electrical component is fixed;
a second case (12) fastened to the first case and fixed with the second electrical component in a state in which the terminal block is electrically connected;
has
The first electrical component and the second electrical component have opposing portions (43a, 51a) that are aligned in an insertion direction in which a portion of the terminal block is inserted into the opening and face each other,
The facing portion of the first electrical component is defined as a first facing portion (43a), and the facing portion of the second electrical component is defined as a second facing portion (51a),
The shortest separation distance (L1) between the first facing portion and the second facing portion in the insertion direction is greater than an insertion amount (L2) for inserting the terminal block into the opening from the inside of the case (L2) for power conversion. A method of manufacturing a device, comprising:
a first fixing step (S12) of fixing the first electrical component to the first case;
a second fixing step (S22) of electrically connecting the second electrical component to the terminal block and fixing the second electrical component to the second case;
After the first fixing step and the second fixing step, the first case and the second case are inserted from the fastening position so that the entire terminal block exists outside the opening. A pre-arrangement step (S30) of relatively shifting and arranging in the direction;
an inserting step (S40) of inserting a portion of the terminal block into the opening by relatively moving the first case and the second case in the inserting direction after the pre-arranging step;
a case fastening step (S50) of fastening the first case and the second case to each other after the inserting step;
A method of manufacturing a power conversion device comprising:

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