专利摘要:
The present invention relates to a vehicle (100) including an engine housing (90) that accommodates wheel drive motors (91a, 91b), and a power control unit (2, 102, 202) attached to the motor housing (90). power control unit (2, 102, 202) includes: a stacked unit (40) wherein multiple power modules (6) accommodate power semiconductor elements for power conversion and multiple chillers (46) are stacked; and reactors (4a, 4b). the stacked unit (40) is disposed in the housing (20) of the power control unit (2, 102, 202) such that the stacking direction of the power modules (6) and chillers (46) is directed toward the longitudinal direction of the vehicle. the reactors (4a, 4b) are arranged in the housing (20) so as not to overlap with the stacked unit (40) as viewed from the stacking direction.
公开号:BR102018006007A2
申请号:R102018006007-4
申请日:2018-03-26
公开日:2018-12-18
发明作者:Keisuke SAWAZAKI;Kenshi Yamanaka;Ryusuke Baba;Hiromi Yamasaki;Hitoshi Imura;Hideaki Tachibana
申请人:Toyota Jidosha Kabushiki Kaisha;Denso Corporation;
IPC主号:
专利说明:

DESCRIPTION REPORT OF THE INVENTION PATENT FOR VEHICLE.
BACKGROUND OF THE INVENTION
1. Field of Invention [001] A technique disclosed in the present specification is related to a vehicle. In particular, the technique relates to a vehicle equipped with motors for driving the wheels.
2. Description of Related Art [002] A vehicle equipped with motors for driving the wheels includes a power control unit using electrical energy from a power source, in order to control the electrical energy for driving the motors. Hereinafter, a vehicle including motors for driving the wheels is referred to as an electric automobile in some cases, and motors for driving the wheels are referred to simply as motors in some cases. In electric automobiles, power control units are attached to the engine housing in order to shorten the energy pipes to supply electric power to the engines in some cases (Publication of Japanese Patent Application No. 2015-204688 and Publication of Patent Application Japanese No. 2013-066259).
[003] Each of the power control unit in JP 2015204688 A and the power control unit in JP 2013-066259 A include: a stacked unit in which multiple power modules accommodate semiconductor power elements for converting electricity, and multiple coolers are stacked; and reactors. The stacked unit is arranged inside a power control unit housing in such a way that the stacking direction of the power modules and coolers is directed towards the longitudinal direction of the vehicle. The reactors are arranged at the rear of the stacked unit.
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2/27
SUMMARY OF THE INVENTION [004] In an electric car equipped with large production engines, a power control unit handles greater electrical energy. As the electrical energy handled by the power control unit becomes greater, an all-energy semiconductor element charge becomes greater. In order to reduce one charge per semiconductor energy element, two or more semiconductor energy elements are connected in parallel in some cases. Alternatively, in an electric car in which multiple motors are installed, an inverter circuit and others are required in each of the motors, and thus more semiconductor elements of energy are required. That is, there are some electric automobiles that require many power modules that accommodate semiconductor energy elements. As the number of power modules that are stacked in the stacked unit increases, a length in the stacking direction of the stacked unit becomes longer. If the stacked unit and reactors are arranged in the stacking direction, the total length of the power control unit becomes longer. When the power control unit is arranged in the vehicle such that the stacking direction of the power modules and the chillers is directed towards the longitudinal direction of the vehicle, a major limitation for installation can be caused by the power control unit that is extends in the longitudinal direction. A technique to reduce a length in the longitudinal direction of the vehicle from a power control unit installed in a vehicle has been desired.
[005] One aspect of the present invention relates to a vehicle. The vehicle includes: a power supply; an engine housing; and a power control unit. The motor housing accommodates motors for driving the wheels. The control unit
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3/27 power is attached to the motor housing. The power control unit is configured to control the electrical energy for driving the motors by using electrical energy from the power supply. The power control unit includes: reactors; and a stacked unit in which multiple power modules and coolers are stacked. The multiple power modules accommodate semiconductor power elements for converting electrical energy. The stacked unit is arranged such that in a power control unit housing, a stacking direction of the power modules, and the coolers are directed towards the longitudinal direction of the vehicle. The reactors are arranged, in the enclosure, in positions where the reactors do not overlap with the stacked unit, as seen from the stacking direction. With the above configuration, it is possible to reduce the length in the longitudinal direction of the vehicle from the power control unit installed in the vehicle. Hereafter, for convenience of explanation, a casing surface of the power control unit installed in the vehicle, the surface being directed towards the front direction of the vehicle is referred to as a front surface, and a housing surface directed towards the rear direction of the vehicle is referred to as a rear surface. In addition, an enclosure surface installed in the vehicle directed towards the right direction of the vehicle is referred to as the right side surface, and an enclosure surface directed towards the left direction of the vehicle is referred to as a left side surface. Here, the vehicle in the right direction (the right side surface) means the right side (the right side surface) in a posture directed towards the front direction of the vehicle, and the left vehicle (the left side surface) means the right side. (the left side surface) in a posture directed towards the front direction of the vehicle. When any of the surface
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4/27 on the right side and the surface on the left side is indicated without being distinguished from each other, this is referred to simply as a lateral side surface.
[006] In the above vehicle, the power control unit may include first voltage converting circuits and inverter circuits. The first voltage converter circuits can be configured to reinforce the voltage of the power supply. The inverter circuits can be configured to convert electrical output energy from the first voltage converter circuits into alternating current. A first capacitor can be connected between a first positive electrode terminal and a first negative electrode terminal which are located on the power supply side of the first voltage converter circuits. A second capacitor can be connected between a second positive electrode terminal and a second negative electrode terminal on the side of the inverter circuit of the first voltage converter circuits. The first capacitor and the second capacitor can be arranged, in the housing, on the same side in the direction of the vehicle width, so as to be adjacent to the stacked unit. In the vehicle described above in JP 2015-204688 A, the first capacitor is disposed adjacent to the stacked unit in the direction of the vehicle width, and the stacked unit, the reactors, and the second capacitor, are disposed in the stacking direction. The first capacitor and the second capacitor are arranged on the same side in the direction of the vehicle width to be adjacent to the stacked unit, to thereby further reduce the length in the vehicle's longitudinal direction of the power control unit installed in the vehicle.
[007] The vehicle above may also include: a rear engine; and an auxiliary device battery. The engines can be used to drive the front wheels. The engine housing can be installed in a front compartment of the vehicle. The power control unit
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5/27 can also include: a rear inverter circuit; and a second voltage converter circuit. The rear inverter circuit can be configured to convert direct current electrical energy to drive electrical energy from the rear motor to drive the rear wheels. The second voltage converter circuit can be configured to decrease the voltage of the power supply, and provide this voltage to the battery of the auxiliary device. The second voltage converter circuit can be arranged at the rear of the reactors in the enclosure. A rear engine connector connected to a rear engine power cable that transmits electrical power to the rear engine can be provided on one surface of the enclosure, and the surface provided with the rear engine connector can be directed towards the rear direction of the engine. vehicle. An auxiliary device battery connector connected to an auxiliary device battery power cable that transmits electricity from the second voltage converter circuit to the auxiliary device battery, can be provided on one surface of the enclosure, and the surface provided with the battery connector of the auxiliary device it can be directed towards the direction of the vehicle width. By providing the rear motor connector to the rear surface of the enclosure, it is possible to shorten the rear motor cable. In addition, by the provision of the rear motor connector, which is provided on the side-side surface of the enclosure in the related art, for the rear surface, it is possible to provide the battery connector of the auxiliary device to the side-side surface of the enclosure. This makes it easier to connect the second voltage converter circuit and the battery connector of the auxiliary device that are arranged in the rear positions inside the enclosure. As a result, it is possible to eliminate wiring for connection of the circuit board located in a higher position in the enclosure and the low voltage connector to the second voltage converter circuit.
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6/27 [008] The vehicle above may also include an air conditioner. The main power connector connected to the main power cable that supplies electrical power from the power source to the power control unit, can be provided on one surface of the enclosure, and the surface provided with the main power connector can be routed in towards the rear direction of the vehicle. An air conditioning connector can be provided in a rear position on a side surface of the enclosure, and the side surface provided with the air conditioning connector can be directed towards the width of the vehicle, and can be located closer to the vehicle. main power connector. The air conditioning connector can be electrically connected to the main power connector inside the housing. The air conditioning connector can be connected to an air conditioning cable that supplies the electrical power from the power supply to the air conditioner. The main power connector and the air conditioning connector are arranged to be adjacent to each other with the corner of the power control unit interposed between them, in order to shorten the connection path between both.
[009] In the vehicle above, the main power connector connected to the main power cable that supplies the electrical power from the power supply to the power control unit, can be provided on one surface of the enclosure, and the surface provided with the connector main power can be directed towards the rear direction of the vehicle. The first capacitor can be arranged in front of the main power connector, as seen from above, and the first capacitor and the main power connector can be connected together. With this configuration, it is possible to shorten the connection path between the first capacitor and the main power connector.
[0010] In the vehicle, the reactors can be arranged under the unit
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7/27 stacked. The power control unit may further include a circuit board on which an electrical power control circuit is mounted can be arranged above the stacked unit. The stacked unit and the reactors, which generate a large amount of heat, are used together with coolers using liquid refrigerant in some cases. The circuit board on which the electrical power control circuits are mounted is arranged above the reactors and the unit is stacked, to thereby suppress the circuit board from coming into contact with the liquid even if the liquid leaks from the coolers. The circuit board is placed in a higher position in the space inside the enclosure (immediately under the top cover), making it possible to facilitate the replacement and maintenance operation of the circuit board.
[0011] The engine housing and the power control unit are typically installed in the front compartment of the vehicle. The details and additional modifications to the technique disclosed in this specification will be described in the Detailed Description of the Achievements as shown below.
BRIEF DESCRIPTION OF THE DRAWINGS [0012] Characteristics, advantages, and technical and industrial significance of exemplary embodiments of the invention will be described below with reference to the accompanying drawings, in which similar numerals denote similar elements, and in which:
[0013] FIG. 1 is a block diagram of an electric car electrical system (hybrid vehicle) of an embodiment;
[0014] FIG. 2 is a plan view showing arrangements of electrical devices in the hybrid vehicle;
[0015] FIG. 3 is a plan view showing a device layout of a front compartment;
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8/27 [0016] FIG. 4 is a plan view showing a layout of the device within a power control unit housing;
[0017] FIG. 5 is a side view showing the layout of the device inside the enclosure of the power control unit;
[0018] FIG. 6 is a front view showing the layout of the device inside the housing of the power control unit;
[0019] FIG. 7 is a front view showing a first variation of a device layout within the power control unit housing;
[0020] FIG. 8 is a plan view showing a second variation of the device layout within the power control unit housing; and [0021] FIG. 9 is a side view showing the second variation of the device layout within the power control unit housing.
DETAILED DESCRIPTION OF THE ACCOMPLISHMENTS [0022] With reference to the drawings, an electric car of one embodiment will be described. The electric car of the embodiment is a hybrid vehicle that includes one engine and three engines as driving sources for displacement. First, an electric power system for a hybrid vehicle 100 will be described. FIG. 1 shows a block diagram of an electric power system for the hybrid vehicle 100. The hybrid vehicle 100 includes two engines (a first front engine 91a, a second front engine 91b), which drives the front wheels, and a rear engine 91c that drives the rear wheels. Hereinafter, for simplicity of description, the first front engine 91a is referred to as a first F 91a engine, and the second front engine F 91b is referred to as a second F 91b engine. Also, when the front engines and the rear engine are mentioned without being
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9/27 tinged with each other, they are referred to simply as 91 engines. Note that an electric car or a hybrid vehicle is an example of a vehicle in the present disclosure.
[0023] The three motors 91 are controlled by a power control unit (PCU) 2. The PCU 2 generates electrical power for the respective three motors 91 through the use of electrical energy from a main battery 80. The PCU 2 includes three voltage converter circuits 10a, 10b, 14, three inverter circuits 12a, 12b, 13, and an electrical power control circuit 15. Main battery 80 is an example of a power supply in the present disclosure.
[0024] The voltage converter circuits 10a, 10b will be described. The voltage converter circuits 10a, 10b are connected in parallel. Voltage converter circuits 10a, 10b can perform a boost operation to boost voltage from the main battery 80, and provide this to the inverter circuits 12a, 12b, 13 and a decrease operation to decrease the voltage of regenerative electrical energy (electrical energy generated by the motors 91) sent from the inverter circuits 12a, 12b, 13, and supply this to the main battery 80. The voltage converter circuits 10a, 10b are so called bidirectional DC / DC converters. The terminals on the main battery side 80 of the voltage converter circuits 10a, 10b are referred to as a positive low voltage electrode terminal 11a and a negative low voltage electrode terminal 11b; and terminals on the side of the inverter circuits 12a, 12b, 13 of the voltage converter circuits 10a, 10b are referred to as a positive high voltage electrode terminal 11c, and a negative high voltage electrode terminal 11d.
[0025] The voltage converter circuit 10a includes two internal transistors 5a, 5b, two free diodes 8a, 8b, and a reactor 4a. The two internal transistors 5a, 5b are connected in series, and the free diodes
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8a, 8b are connected in antiparallel with the respective internal transistors 5a, 5b. The reactor 4a is connected between a midpoint of the series connection between the two internal transistors 5a, 5b and the positive low voltage electrode terminal 11a. The serial connection between the two internal transistors 5a, 5b is connected between the positive high voltage electrode terminal 11c and the negative high voltage electrode terminal 11d. The low voltage negative electrode terminal 11b is directly connected to the high voltage negative electrode terminal 11d. The power transistor 5b at a lower position in FIG. 1 is primarily in charge of the impulse operation, and the power transistor 5a in a higher position in the drawing is primarily in charge of the dimming operation. The operation of the voltage converter circuit 10a in FIG. 1 is well known, and its specific description will be omitted.
[0026] The voltage converter circuit 10b includes two internal transistors 5c, 5d, and two free diodes 8c, 8d, and a reactor 4b. The voltage converter circuit 10b has the same structure as that of the voltage converter circuit 10a, and therefore its description will be omitted.
[0027] The positive low voltage electrode terminal 11a of the voltage converter circuit 10a and the negative low voltage electrode terminal 11b of the voltage converter circuit 10b are connected to a main power connector 24 of the PCU 2. A main power 31 which sends electrical power from main battery 80 to PCU 2 is connected to main power connector 24. In other words, main battery 80 is connected to voltage converter circuits 10a, 10b, via the main power cable 31 and the main power connector 24.
[0028] A filter capacitor 3 is connected between a terminal on the main battery side 80 of the voltage converter circuits 10a,
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10b, that is, the positive low voltage electrode terminal (an example of a first positive electrode terminal) 11a and the negative low voltage electrode terminal (an example of a first negative electrode terminal) 11b. A leveling capacitor 7 is connected between terminals on the inverter circuit side of the voltage converter circuits 10a, 10b, that is, the positive high-voltage electrode terminal (an example of a second positive electrode terminal) 11c and the high voltage negative electrode (an example of a second negative electrode terminal) 11d.
[0029] The reason why PCU 2 includes the two voltage converter circuits 10a, 10b that are connected in parallel is to reduce a load per power transistor.
[0030] The two internal transistors 5a, 5b which are connected in series, and the two free diodes 8a, 8b are accommodated in a single package, and this package is referred to as a power module 6a. The two internal transistors 5c, 5d which are connected in series, and the two free diodes 8c, 8d are also accommodated in a single package, and this package is referred to as a power module 6b.
[0031] The inverter circuit 12a will be described. Inverter circuit 12a includes six power modules 6c at 6h each of which is the same as power module 6a. FIG. 1 shows only internal structures of the power modules 6c, 6d, and illustrations of internal structures of the other power modules 6e to 6h are omitted. Power modules 6c to 6h are connected in parallel. As shown in FIG. 1, two internal transistors 5e, 5f are connected in series to each of the power module 6c and the power module 6d. A free diode 8e is connected in antiparallel with the power transistor 5e, and the free diode 8f is connected in antiparallel with the power transistor 5f, respectively. Respective midpoints of connections in
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12/27 series of internal transistors 5e, 5f are connected together. The respective two internal transistors 5e of the power modules 6c, 6d located in upper positions in FIG. 1 are controlled to operate synchronously. The respective two internal transistors 5f of the power modules 6c, 6d located at lower positions in FIG. 1 are controlled to operate synchronously. That is, the respective power modules 6c, 6d are controlled to operate synchronously, so that they function as a single power module. The two power modules 6c, 6d are controlled to operate synchronously in order to reduce a load per power transistor.
[0032] The respective power modules 6e, 6f have the same connection structures as the structures of the power modules 6c, 6d. The respective power modules 6g, 6h also have the same connection structures as the structures of power modules 6c, 6d. Alternating current is admitted from a midpoint of the series connection between the power transistors 5e, 5f of the power module 6c, and a midpoint of the series connection between the power transistors 5e, 5f of the power module 6d. Alternating current is also permitted from a midpoint of the series connection between the power transistors of the power module 6e, and a midpoint of the series connection between the power transistors of the power module 6f. Alternating current is admitted from a midpoint of the series connection between the power transistors of the 6g power module, and a midpoint of the series connection between the power transistors of the 6h power module, as well. Each of the alternating currents of these three types has a phase difference of 120 degrees, and the alternating currents of these three types make up a three-phase current. For the control of power modules 6e, 6f to operate synchronously, and for the control of power modules 6g, 6f to operate synchronously. Petition 870180024111, of 26/03/2018, pg. 91/112
13/27 it is possible to reduce a load per power transistor.
[0033] An internal cable that transmits the three-phase alternating current of the inverter circuit 12a is connected to a front motor connector 27. From now on, when power modules 6a to 6h are mentioned without being distinguished from one another, these Power modules are referred to simply as power modules 6. The respective inverter circuits 12b, 13 described later also include the same power modules. These power modules are also referred to as power modules 6.
[0034] The inverter circuit 12b has the same structure as that of the inverter circuit 12a, and an illustration of a circuit configuration of the inverter circuit 12b is omitted in FIG. 1. The 12b inverter circuit also includes six power modules 6. An internal cable that transmits the three-phase alternating current from the 12b inverter circuit is also connected to the front motor connector 27. The front motor connector 27 is a connector to which a power cable from the front motor 32 that transmits electrical energy to the two motors (the first motor F 91a and the second motor F 91b) involved with driving the front wheels 81 (see FIG. 2) is connected. The first F 91a engine and the second F 91b engine are supplied with electricity from PCU 2, via the front engine connector 27 and the front engine power cable 32.
[0035] The inverter circuit 13 generates electric power for driving the rear motor 91c that drives the rear wheels 82 (see FIG. 2). Inverter circuit 13 is connected to the high voltage positive electrode terminal 11c of the voltage converter circuit 10a and to the high voltage negative electrode terminal 11d of the voltage converter circuit 10b. The inverter circuits 12a, 12b are configured such that the two power modules 6 operate in parallel, and the inverter circuit 13 includes three power modules in order to generate alternating currents, each
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14/27 having a 120 degree phase difference. This is because the rear engine 91c has a smaller output compared to that of the first F 91a engine and the second F 91b engine. The internal cable that transmits the three-phase alternating current from the inverter circuit 13 is connected to a rear motor connector 23. The rear motor connector 23 is a connector to which a rear motor power cable 33 that transmits electrical power to the motor rear 91c that drives the rear wheels 82 is connected. The rear engine 91c is supplied with electricity from PCU 2, via the rear engine connector 23 and the rear engine power cable 33.
[0036] The voltage converter circuit 14 will be described. The voltage converter circuit 14 is an electrical isolation type converter that converts the voltage, via a transformer, different from the voltage converter circuits 10a, 10b. The electrical isolation converter is well known, so a specific circuit diagram is omitted. The voltage converter circuit 14 is connected to the main battery 80, via the main power connector 24. The voltage converter circuit 14 decreases the voltage of the main battery 80 to a voltage of the battery of the auxiliary device 97, and provides this to the battery auxiliary device 97. The auxiliary device 97 battery is a battery that supplies electrical power to devices operating at low voltages, such as a car audio system and ambient light. Devices that receive the power supply from the battery of auxiliary device 97 in order to operate are collectively referred to as auxiliary devices. An electrical power control circuit 15 (described later) of PCU 2 belongs to auxiliary devices.
[0037] The voltage converter circuit 14 is connected to the battery of auxiliary device 97, via an AMD 25 connector provided in a PCU 2 housing. The voltage converter circuit 14 operates in response
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15/27 ta to a command received from an HV 95 control unit which is a superordinate control unit for PCU 2. The voltage converter circuit 14 and the HV 95 control unit are connected to each other via a DDC signal connector 26 provided in the PCU 2 enclosure.
[0038] The power transistors of the voltage converter circuits 10a, 10b, the inverter circuits 12a, 12b, 13 operate in response to the commands received from the electrical power control circuit 15. The electrical power control circuit 15 is connected to the HV 95 control unit and the auxiliary device battery 97, via a low voltage connector 22. The electrical control circuit 15 receives the power supply from the battery of the auxiliary device 97, and operates at response to a command received from the HV 95 control unit.
[0039] PCU 2 functions as a relay that transmits electrical energy from main battery 80 to an air conditioner 94. An air conditioning connector 21 is provided in the housing of PCU 2. The air conditioning connector 21 is connected to the main energy 24 inside the enclosure. PCU 2 relays the electrical energy from the main battery 80, and sends it to the air conditioner 94.
[0040] The PCU 2, the first F 91a engine, and the second F 91b engine are installed together with the engine, in a front compartment of the vehicle. FIG. 2 shows a plan view of the hybrid vehicle 100.
[0041] A coordinate system in each drawing will be described. An arrow on an F axis indicates a front direction of the vehicle, an arrow on a V axis indicates an upward direction of the vehicle, and an arrow on an H axis indicates a right direction of the vehicle. The right side and the left side are defined based on a posture directed towards the front direction of the vehicle. The direction of the H axis can be expressed as the direction of the vehicle width.
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16/27 [0042] Engine 96, a drive shaft 90, air conditioner 94, and auxiliary device battery 97 are installed in the front compartment 99 of the hybrid vehicle 100. The first F 91a engine and the second engine F 91b are accommodated in the drive shaft housing 90. Consequently, the drive shaft 90 can be referred to as a motor housing. The drive shaft 90 and motor 96 are coupled together, and are suspended on two side members not shown. An axle 98 of the front wheels extends through the drive shaft housing 90 and the motor housing 96.
[0043] PCU 2 is attached to the drive shaft 90 (the motor housing). Since the PCU 2 is arranged on the drive shaft 90, the power cable of the front motor 32 (see FIG. 1) that connects the PCU 2 to the first and second F 91a, 91b motors may be shorter.
[0044] The battery of the auxiliary device 97 is placed on the left front part (the lower right part in FIG. 2) of the front compartment 99, and the air conditioner 94 is connected to the right front part (the lower left part in FIG. 2) the same.
[0045] The main battery 80 is arranged under the rear seats, and the rear engine 91c is arranged in a space in the rear seat of the vehicle. The bold lines in FIG. 2 indicate power cables, communication cables, and others. PCU 2 is connected to several devices. With reference to FIG. 3, the connectors included in PCU 2 will be described.
[0046] FIG. 3 is a plan view showing the layout of the device in the front compartment 99, and the electrical connection relationship between PCU 2 and the other devices. First, respective surfaces of housing 20 of PCU 2 will be defined. In the front compartment 99, a surface of the housing 20 of the PCU 2 fixed on the drive shaft 90, the surface being directed towards the front direction of the
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17/27 vehicle, is referred to as a front surface 20a. A surface of the housing 20 directed towards the rear direction of the vehicle is referred to as a rear surface 20b. A surface of the housing 20 directed towards the right direction towards the width of the vehicle is referred to as a surface on the right side 20c, and a surface of the housing 20 directed towards the left towards the width of the vehicle is referred to as a surface left side 20d. When the right side surface 20c and the left side surface 20d are indicated without being distinguished from each other, they are referred to as simply side-side surfaces.
[0047] The enclosure 20 is provided with seven connectors. The main power connector 24 and the rear motor connector 23 are provided on a rear surface 20b of the housing 20. The front motor connector 27, the AMD connector 25, and a DDC signal connector 26 are provided on the surface of the housing. left side 20d of housing 20. The air conditioner connector 21 is provided on the surface of the right side 20c of housing 20. Low voltage connector 22 is provided on the top surface of housing 20.
[0048] The main power cable 31 that transmits electrical power from the main battery 80 is connected to the main power connector 24. The rear motor power cable 33 that transmits electrical power to the rear motor 91c is connected to the motor connector rear 23. The front engine power cable 32 that transmits electrical power to the first F 91a engine and the second F 91b engine is connected to the front engine connector 27. Note that the front engine power cable 32 is routed under the front motor connector 27, and thus the front motor power cable 32 is not visible in FIG. 2 and FIG. 3.
[0049] A cable (an example of an auxiliary device battery power cable) 34 that transmits electrical energy from the circuit
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18/27 voltage converter 14 inside PCU 2 to the auxiliary device 97 battery is connected to the AMD 25 connector. The auxiliary device 97 battery and PCU 2 are connected to each other via the low voltage connector 22. A electrical power is supplied from the auxiliary device battery 97, via the low voltage connector 22 to the electrical power control circuit 15 (see FIG. 1) inside housing 20. [0050] A communication cable communicates with the HV 95 control unit is connected to the DDC 26 signal connector. The HV 95 control unit and the voltage converter circuit 14 are connected to each other via the DDC 26 signal connector. HV 95 and PCU 2 are connected to each other via the low voltage connector 22. A command is sent from the HV 95 control unit via the low voltage connector 22 to the power control circuit 15 (see FIG. 1) inside the housing 20.
[0051] A cable that transmits electricity to the air conditioner 94 is connected to the air conditioner connector 21. The air conditioner connector 21 is connected to the main power connector 24 inside the housing 20. The housing 20 of the PCU 2 works like a relay that sends the electricity from the main battery 80 to the air conditioner 94.
[0052] In the hybrid vehicle 100, the cables 31, 33 connected to the devices (the main battery 80, the rear engine 91c) arranged at the rear of the vehicle are connected to the connectors (the main power connector 24, the rear engine connector 23) provided on the rear surface 20b of the housing 20 of the PCU 2. A cable 35 connected to the air conditioner 94 disposed on the right front of the vehicle (bottom left in FIG. 3) is connected to the connector (the air conditioning connector 21 ) provided on the surface of the right side 20c of the housing 20. A cable 34 connected to the battery of the auxiliary device 97 disposed on the left front of the vehicle (the bottom right
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19/27 in FIG. 3) is connected to the connector (the AMD 25 connector) provided on the left side surface 20d of the housing 20. In this way, in the hybrid vehicle 100, many of the connectors of PCU 2 are provided on the surfaces of PCU 2 next to the devices that are cable connection destinations.
[0053] Two tubes (a refrigerant supply tube 31a and a refrigerant discharge tube 31b) are connected to the front surface 20a of housing 20. The two tubes are connected to a refrigerant circulation apparatus not shown.
[0054] With reference to FIG. 4 to FIG. 6, a layout of the device within the housing 20 of the PCU 2 is described. FIG. 4 is a plan view of the housing 20 with a top cover of the housing 20 in section. FIG. 5 is a side view of the housing 20 with a left side plate of the housing 20 in section. FIG. 6 is a front view of the housing 20 with a front plate of the housing 20 in section. In FIG. 4, an illustration of a circuit board 45 (described later) arranged above a stacked unit 40 will be omitted. In FIG. 5, an illustration of a current sensing unit 44 (described later) is omitted. FIG. 4 to FIG. 6 are drawings explaining the layout of the device inside the housing 20, and show the respective devices schematically in single figures. Illustrations of connections between the respective devices and components used for fixing the devices are not illustrated.
[0055] The stacked unit 40, a capacitor unit 42, the current sensing unit 44, the two reactors 4a, 4b, a voltage converter unit 41, are accommodated inside the enclosure 20.
[0056] Stacked unit 40 will be described. Stacked unit 40 is a unit formed by stacking multiple power modules 6 and multiple coolers 46. In FIG. 4 and FIG. 5, reference numerals 6 are added to only the two power modules
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Leftmost 20/27, and reference numerals for the other power modules are omitted. In addition, in FIG. 4 and FIG. 5, reference numerals 46 are added to only the two leftmost coolers, and reference numerals for the other coolers are omitted. The multiple power modules 6 of the stacked unit 40 correspond to the power modules 6a to 6h, and the power module included in the inverter circuit 12b, and the power module included in the inverter circuit 13.
[0057] In stacked unit 40, coolers 46 and power modules 6 are stacked alternately one by one, and coolers 46 are in contact with both sides of the respective power modules 6. Flow passages where a liquid refrigerant flows are formed inside the coolers 46. The refrigerant supply tube 31a and the refrigerant discharge tube 31b extend through the multiple coolers 46 of the stacked unit 40. The refrigerant is distributed from the refrigerant circulation apparatus not shown, via the refrigerant supply tube 31a. The refrigerant absorbs heat from the adjacent energy modules 6, while the refrigerant flows through the interior of the respective coolers 46. The refrigerant having absorbed the heat is discharged, via the refrigerant discharge tube 31b, to the outside of the stacked unit 40 , and is then returned to the refrigerant circulation apparatus not shown.
[0058] The stacked unit 40 is arranged in housing 20, such that the stacking direction of the power modules 6 and coolers 46 is directed towards the longitudinal direction of the vehicle, as seen from above the housing 20. FIG. 4 corresponds to a view of the housing 20 as seen from above. The two reactors 4a, 4b are arranged under the stacked unit 40 (see FIG. 5, FIG. 6). The voltage converter unit 41 is arranged at the rear of reactors 4a, 4b
Petition 870180024111, of March 26, 2018, p. 99/112
21/27 (see FIG. 5). The voltage converter unit 41 is a unit that accommodates the voltage converter circuit 14 described in FIG. 1.
[0059] The capacitor unit 42 is arranged on the right side (the top side in FIG. 4, the left side in FIG. 6) of the stacked unit 40. The capacitor unit 42 accommodates the filter capacitor 3 and the filter capacitor. leveling 7 described in FIG. That is, inside the housing 20, the filter capacitor 3 and the leveling capacitor 7 are arranged adjacent to the stacked unit 40 on the same side (on the right side of the vehicle) in the direction of the vehicle width.
[0060] The main power connector 24 is provided in a rear position on the rear surface 20b of housing 20. The air conditioning connector 21 is provided in a position on the rear of the surface on the right side 20c of housing 20. As described in FIG. 1, the main power connector 24 is connected to the air conditioning connector 21 inside the housing 20. In other words, the air conditioning connector 21 is provided on the side side surface of the housing 20, and in a position at the rear of this. side side surface (the right side surface 20c) closest to the main power connector 24. The air conditioner connector 21 is a connector that connects the air conditioner cable (35) that supplies electricity from the main battery 80 to the conditioner of air 94.
[0061] As clearly shown in FIG. 4, the filter capacitor 3 is located in front of the main power connector 24, as seen from above. As described in FIG. 1, the main power connector 24 and the filter capacitor 3 are connected together. Dashed lines in bold L1 in FIG. 4 indicate connection paths between the main power connector 24, the air conditioner connector 21, and the filter capacitor 3. As shown by the dashed lines in bold L1 in FIG. 4, the above layout allows the connection paths between the main power connector 24, the conec
Petition 870180024111, of March 26, 2018, p. 100/112
22/27 air conditioning tor 21, and filter capacitor 3, are shorter. In particular, because the main power connector 24 and the air conditioning connector 21 are adjacent to each other with a corner of the housing 20 interposed between them, the connection paths between them become shorter.
[0062] As shown in FIG. 4 and FIG. 6, the current sensing unit 44 is arranged on the left side of the stacked unit 40. Buses (not shown) that send the admitted three-phase alternating current from the inverter circuits 12a, 12b pass through the current sensing unit 44, and reach the front motor connector 27. Current sensing unit 44 measures the current flowing through the respective busbars (i.e., three-phase alternating current supplied to the first and second F 91a, 91b motors).
[0063] As shown in FIG. 5, FIG. 6, circuit board 45 is arranged above stacked unit 40. Circuit board 45 is an electronic component to which the power control circuit 15 described in FIG. 1 is mounted. The low voltage connector 22 is provided on the upper surface of the enclosure 20, and, as mentioned before, the electrical control circuit 15 mounted on circuit board 45 receives the electrical supply from the battery of auxiliary device 97, via the low voltage connector 22. In addition, the electrical control circuit 15 receives a command from the HV control unit 95, via the low voltage connector 22. As long as the circuit board 45 and the connector low voltage connections 22 are arranged to be close together, and in this way it is possible to shorten the connection path between circuit board 45 and the low voltage connector 22.
[0064] As shown in FIG. 5 and FIG. 6, inside the housing 20, the reactors 4a, 4b are arranged in positions where the reactors 4a, 4b do not overlap with the stacked unit 40, as seen
Petition 870180024111, of March 26, 2018, p. 101/112
23/27 to from the stacking direction (the direction of the F axis in FIG. 5 and FIG. 6) of the stacked unit 40. Respective both ends in the stacking direction of the stacked unit 40 face the inner wall surfaces of the housing 20 In other words, both ends in the stacking direction of stacked unit 40 are close to the surfaces of the inner wall of housing 20. Stacked unit 40 is a stacked body of multiple power modules 6 and multiple coolers 46, and has a longer length in the stacking direction. If at least one of the reactors 4a, 4b is arranged in such a way as to overlap with the stacked unit 40 in the stacking direction, the length in the longitudinal direction of the housing 20 becomes longer. The PCU 2 of the hybrid vehicle 100 of the embodiment is arranged such that both reactors 4a, 4b do not overlap with the stacked unit 40, as seen from a direction of the F axis (the stacking direction), and the respective ends in the stacking direction of the stacked unit 40 face the surfaces of the inner wall of the enclosure 20, in order to reduce the length in the longitudinal direction of the vehicle of the enclosure 20.
[0065] The description: reactors 4a, 4b are arranged in positions where reactors 4a, 4b that do not overlap with stacked unit 40, as seen from the stacking direction of stacked unit 40, can be expressed as follows. That is, reactors 4a, 4b are arranged away from an extension from stacked unit 40. Alternatively, reactors 4a, 4b are arranged in positions that deviate from the stacking direction of stacked unit 40. Reactors 4a, 4b used in the PCU 2 for driving the wheels are large in size, and thus they cause great influence on the length in the longitudinal direction of the housing 20. In the PCU 2 of the embodiment, by improving the arrangement of the reactors configured above 4a, 4b, the length at di
Petition 870180024111, of March 26, 2018, p. 102/112
24/27 the vehicle's longitudinal reaction of the wrapper 20 can be successfully reduced.
[0066] The two capacitors (the filter capacitor 3, the leveling capacitor 7) are arranged in such a way that they do not overlap with the stacked unit 40, as seen from the stacking direction (the direction of the F axis in FIG, 5 and FIG. 6). This contributes to the reduction in length in the longitudinal direction of the vehicle of the housing 20 of the PCU 2.
[0067] In PCU 2 of the embodiment, the circuit board 45 on which the circuits are mounted is arranged above the stacked unit 40. As mentioned above, liquid refrigerant flows through the stacked unit 40. Liquid can leak from the stacked unit 40 Since circuit board 45 is arranged above stacked unit 40, circuit board 45 is prevented from being subjected to liquid even if liquid leaks from stacked unit 40.
[0068] A first variation of the device layout inside the PCU 2 enclosure will be described. FIG. 7 shows a front view of the device layout within the housing 20 of a PCU 102. The same reference numerals are added to the same components as those in FIG. 6. In this example, reactor 4a is arranged on the right side of the vehicle (on the left side in FIG. 7) of the stacked unit 40, as seen from the stacking direction (the direction of the F axis in FIG. 7). Reactor 4b is disposed in a position more at the rear of the vehicle than reactor 4a. In addition, capacitor unit 42 (filter capacitor 3, leveling capacitor 7) are arranged under stacked unit 40. Also in this variation, reactors 4a, 4b are arranged not to overlap with stacked unit 40, as viewed from the stacking direction (the direction of the F axis in FIG. 7). Capacitor unit 42 (filter capacitor 3 and leveling capacitor 7) is also arranged
Petition 870180024111, of March 26, 2018, p. 103/112
25/27 not to overlap with the stacked unit 40, as seen from the stacking direction. The respective both ends in the stacking direction of the stacked unit 40 face the inner wall surfaces of the wrapper 20. In other words, the respective both ends in the stacking direction of the stacked unit 40 are close to the inner wall surfaces of the wrapper 20. In this variation, since reactors 4a, 4b, and filter capacitor 3, as well as leveling capacitor 7, are not aligned to the stacked unit 40 in the stacking direction, it is possible to reduce the length in the longitudinal direction of the PCU 102 vehicle .
[0069] The second variation of the device layout inside the PCU 2 enclosure will be described. FIG. 8 shows a plan view of the device layout inside the housing 20 of a PCU 202. FIG. 9 shows a side view of the device layout within the housing 20 of the PCU 202. The same reference numerals are added to the same component as those of the PCU 2 shown in FIG. 4 and FIG. 5. PCU 202 is installed in a compact two-wheel drive electric car. This electric car includes only one motor as a drive source for displacement. Consequently, a stacked unit 240 of PCU 202 has fewer power modules 6 than that of stacked unit 40 of PCU 2 described above. Consequently, the length in the stacking direction of the stacked unit 240 is shorter than the length in the stacking direction of the stacked unit 40. However, housing 20 of PCU 202 uses a housing of the same type as the housing of PCU 2 described above. . Consequently, in housing 20 of PCU 202, there is a larger space Sp adjacent to stacked unit 240 in the stacking direction (the direction of the F axis in FIG. 8 and FIG. 9). In this way, because no reactor is present in the stacking direction of the unit
Petition 870180024111, of March 26, 2018, p. 104/112
26/27 stacked, it becomes easier to increase or decrease the number of power modules in the stacked unit. Note that in the Sp space in the PCU 202 housing, there may be devices arranged (such as capacitors and power cables, for example) other than the reactors.
[0070] Observations pertaining to the technique explained in the implementation will be described. An electrical converter can be installed in a rear space of the vehicle.
[0071] The AMD 25 connector of the embodiment is an example of an auxiliary device battery connector. The filter capacitor 3 of the embodiment is an example of a second capacitor. The drive shaft 90 of the embodiment is an example of an engine housing. Inverter circuit 13 is an example of a rear inverter circuit. The voltage converter circuits 10a, 10b of the embodiment are an example of a first voltage converter circuit. The voltage converter circuit 14 accommodates the voltage converter unit 41 of the embodiment is an example of a second voltage converter circuit.
[0072] It is sufficient that the stacking direction of the power modules 6 and the coolers 46 of the stacked unit 40 is generally directed towards the longitudinal direction of the vehicle. For example, the stacking direction can be slightly tilted from the horizontal line as seen from the direction of the vehicle width, or it can be slightly tilted relative to a straight line that extends in the longitudinal direction as seen from above.
[0073] An electric car (the hybrid vehicle 100) of the embodiment includes the two front engines 91a, 91b and the rear engine 91c for displacement. The technique disclosed in this specification is not limited to the number of displacement engines. It is suitable for applying the technique disclosed in this specification
Petition 870180024111, of March 26, 2018, p. 105/112
27/27 to an electric car including no rear engine. The technique disclosed in this specification may apply to an automobile or fuel cell vehicle including engines, but no engines for displacement.
[0074] The electric car (the hybrid vehicle 100) of the embodiment includes the two reactors 4a, 4b. The technique disclosed in this specification may be applicable to an electric car including a single reactor, or it may be applicable to an automobile including three or more reactors.
[0075] As mentioned above, specific examples of the present invention have been described, but these examples merely illustrate some possibilities of the teachings and do not restrict the claims to them. The technique placed in the claims includes variations and modifications of the specific examples as described above. The technical elements disclosed in this specification or in the drawings may exhibit technical advantages separately, or in various types of combinations, and are not limited to the combinations placed in the claims at the time of filing the order. In addition, the technique exemplified in this specification and in the drawings can achieve a plurality of objectives simultaneously, and the achievement of one of them has technical advantages.
权利要求:
Claims (6)
[1]
1. Vehicle (100), characterized by the fact that it comprises:
a power supply (80);
a motor housing (90) that accommodates motors (91a, 91b) for driving the wheels; and a power control unit (2, 102, 202) attached to the motor housing (90), the power control unit (2, 102, 202) being configured to control the activation of the electric power of the motors (91a, 91b) by the use of electrical energy from the power supply (80), in which the power control unit (2, 102, 202) includes reactors (4a, 4b), and a stacked unit (40) in which power modules multiple (6) and multiple coolers (46) are stacked, the multiple power modules (6) accommodating semiconductor energy elements for converting electricity, the stacked unit (40) is arranged such that in a housing (20) of the unit power control (2, 102, 202), a stacking direction of the power modules (6) and coolers (46) is directed towards a longitudinal direction of the vehicle (100), and the reactors (4a, 4b ) are arranged, in the housing (20), in positions where the reactors (4a, 4b) are not reset with the stacked unit (40) as seen from the stacking direction.
[2]
2. Vehicle (100) according to claim 1, characterized by the fact that the power control unit (2, 102, 202) includes first voltage converter circuits (10a, 10b) and inverter circuits (12a, 12b ), the first voltage converting circuits (10a, 10b) are configured to reinforce the power supply voltage (80), the inverter circuits (12a, 12b) are configured to
Petition 870180024111, of March 26, 2018, p. 107/112
2/4 convert the electrical output energy of the first voltage converting circuits (10a, 10b) into alternating current, a first capacitor (3) is connected between a first positive electrode terminal (11a) and a first negative electrode terminal (11b ) that are located on one side of the power supply of the first voltage converter circuits (10a, 10b), a second capacitor (7) is connected between a second positive electrode terminal (11c) and a second negative electrode terminal (11d ) on one side of the inverter circuit of the first voltage converting circuits (10a, 10b), and the first capacitor (3) and the second capacitor (7) are arranged, in the housing (20), on the same side in a width direction of the vehicle so that they are adjacent to the stacked unit (40).
[3]
3. Vehicle (100), according to claim 1 or 2, characterized by the fact that it still comprises:
a rear engine (91c); and an auxiliary device battery (97), in which the engines (91a, 91b) are for driving the front wheels, the engine housing (90) is installed in a front compartment (99) of the vehicle (100), the unit power control (2, 102, 202) includes a rear inverter circuit (13) and a second voltage converter circuit (14), the rear inverter circuit (13) is configured to convert direct current electrical energy to drive electrical energy of the rear motor (91c) for driving the rear wheels, the second voltage converter circuit (14) is configured to decrease the voltage of the power supply (80), and supply the voltage to the auxiliary device battery (97),
Petition 870180024111, of March 26, 2018, p. 108/112
3/4 the second voltage converter circuit (14) is arranged at the rear of the reactors (4a, 4b) in the housing (20), a rear motor connector (23) connected to a rear motor power cable (33) that transmits electrical energy to the rear engine (91c) is provided on a surface of the enclosure (20), the surface provided with the rear engine connector (23) is directed towards the rear direction of the vehicle (100), and a connector from the rear auxiliary device battery (25) connected to an auxiliary device battery power cable (34) that transmits electrical energy from the second voltage converter circuit (14) to the auxiliary device battery (97) is provided on a surface of the enclosure (20), the surface provided with the auxiliary device battery connector (25) is directed towards the width of the vehicle.
[4]
Vehicle, (100) according to any one of claims 1 to 3, characterized in that it additionally comprises an air conditioner (94), in which the engine housing (90) is installed in a front compartment (99) of the vehicle (100), a main power connector (24) connected to a main power cable (31) that supplies electrical power from the power supply (80) to the power control unit (2, 102, 202) is provided on a surface of the enclosure (20), the surface provided with the main power connector (24) is directed towards the rear direction of the vehicle (100), an air conditioning connector (21) is provided in a position of rear of a side surface of the enclosure (20), the side surface provided with the air conditioning connector (21) is directed towards the direction of the vehicle width, and is located closest to the main power connector (24),
Petition 870180024111, of March 26, 2018, p. 109/112
4/4 the air conditioning connector (21) is electrically connected to the main power connector (24) inside the housing (20), and the air conditioning connector (21) is connected to an air conditioning cable (35) which supplies the electrical energy from the power supply (80) to the air conditioner (94).
[5]
5. Vehicle (100), according to claim 2, characterized by the fact that the engine housing (90) is installed in a front compartment (99) of the vehicle (100), a main power connector (24) connected a main power cable (31) that supplies the electrical power from the power supply (80) to the power control unit (2, 102, 202) is provided on a surface of the enclosure (20), the surface provided with the main power connector (24) is directed towards the rear direction of the vehicle (100), the first capacitor (3) is arranged in front of the main power connector (24) as seen from above, and the first capacitor (3 ) and the main power connector (24) are connected together.
[6]
6. Vehicle (100) according to any one of claims 1 to 5, characterized by the fact that the reactors (4a, 4b) are arranged under the stacked unit (40), and the power control unit (2, 102, 202) further includes a circuit board (45) on which an electrical power control circuit (15) is mounted, the circuit board is arranged above the stacked unit (40).
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法律状态:
2018-12-18| B03A| Publication of a patent application or of a certificate of addition of invention [chapter 3.1 patent gazette]|
优先权:
申请号 | 申请日 | 专利标题
JP2017-067515|2017-03-30|
JP2017067515A|JP6805932B2|2017-03-30|2017-03-30|vehicle|
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