Vehicle drive module having improved terminal design

• US 20030132042A1
• Filed: 09/23/2002
• Published: 07/17/2003
• Est. Priority Date: 01/16/2002
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Kehl, Dennis L., Kannenberg, Daniel G., Kaishian, Steven C., Radosevich, Lawrence D., Beihoff, Bruce C., Phillips, Mark G.
• Granted Patent: US 7,032,695 B2
• Time in Patent Office: Days
• US Class Current: 180/65.1
• CPC Class Codes: B60L 15/007 Physical arrangements or structures of drive train converters specially adapted for the propulsion motors of electric vehicles
• CPC Class Codes: B60L 2210/20 AC to AC converters
• CPC Class Codes: B60L 50/15 with additional electric power supply with capacitors charged by engine-driven generators B60L50/40; with batteries charged by engine-driven generators B60L50/61
• CPC Class Codes: B60L 50/50 using propulsion power supplied by batteries or fuel cells
• CPC Class Codes: H02M 1/44 Circuits or arrangements for compensating for electromagnetic interference in converters or inverters
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H05K 7/20927 Liquid coolant without phase change
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility

Abstract

A terminal structure for vehicle drive power electronics circuits reduces the need for a DC bus and thereby the incidence of parasitic inductance. The structure is secured to a support that may receive one or more power electronic circuits. The support may aid in removing heat from the circuits through fluid circulating through the support. The support may form a shield from both external EMI/RFI and from interference generated by operation of the power electronic circuits. Features may be provided to permit and enhance connection of the circuitry to external circuitry, such as by direct contact between the terminal assembly and AC and DC circuit components. Modular units may be assembled that may be coupled to electronic circuitry via plug-in arrangements or through interface with a backplane or similar mounting and interconnecting structures.

Claims

1. An electric drive for a vehicle at least partially propelled by an electric motor, the drive comprising:

a vehicle drive train;

a power converter assembly operatively coupled to the drive train, the assembly comprising;

a thermal support;

a power converter circuit secured to the thermal support and cooled by the thermal support during operation; and

a terminal element supported on the thermal support and including an electrically insulating but thermally conducting body carrying conductors for transfer of power between the power converter circuit and external circuitry, the terminal element being configured to transfer heat from the conductors via heat transfer to the thermal support during operation.

2. The electric vehicle drive of claim 1, wherein the body is made of a ceramic-filled thermoplastic.

3. The electric vehicle drive of claim 1, wherein the body is made of a liquid crystal polymer.

4. The electric vehicle drive of claim 1, wherein the cooling element includes a conduit for routing a cooling fluid through at least a portion of the body.

5. The electric vehicle drive of claim 1, wherein the cooling element includes a thermal extension for conducting heat from the body.

6. The electric vehicle drive of claim 1, wherein the terminal element comprises a integral structure removably secured to the thermal support.

7. The electric vehicle drive of claim 1, wherein the terminal element includes an insulative body in which the conductors are secured.

8. The electric vehicle drive of claim 1, wherein the terminal assembly includes a two incoming power conductors and three outgoing power conductors.

9. The electric vehicle drive of claim 8, wherein the incoming power conductors are disposed between respective outgoing power conductors.

10. The electric vehicle drive of claim 1, wherein the terminal element is configured to interface with the power converter circuit and with an energy storage or conditioning circuit.

11. The electric vehicle drive of claim 1, wherein the terminal element comprises an electrically insulative and thermally conductive polymer.

12. The electric vehicle drive of claim 1, wherein the terminal element includes integral connection pads for interconnecting the terminal element with the power converter circuit.

13. The electric vehicle drive of claim 1, wherein the terminal element is directly mounted adjacent to an edge of the support.

14. An electric drive for a vehicle at least partially propelled by an electric motor, the drive comprising:

a vehicle drive train;

a power converter assembly operatively coupled to the drive train, the assembly comprising;

a support having a first side, a second side opposite the first side, and an edge extending between the first and second sides;

a terminal assembly disposed adjacent to the edge of the support and including DC input terminals for receiving DC input power and AC output terminals for transmitting AC output power;

a power converter circuit supported on the first side of the support and coupled to the DC input terminals and to the AC output terminals of the terminal assembly; and

an energy storage or conditioning circuit supported on the second side of the support and coupled to the DC input terminals and to the power converter circuit via the terminal assembly.

15. The electric vehicle drive of claim 14, wherein the support at least partially defines a reference plane at a desired electrical potential, and wherein the terminal assembly includes an body at the reference desired electrical potential.

16. The electric vehicle drive of claim 14, wherein the support is a single-piece support.

17. The electric vehicle drive of claim 14, wherein the support is a multi-piece support.

18. The electric vehicle drive of claim 14, wherein the power converter circuit comprises an inverter circuit.

19. The electric vehicle drive of claim 14, wherein the power converter circuit comprises a matrix converter.

20. The electric vehicle drive of claim 14, wherein the energy storage or conditioning circuit includes a capacitor bank.

21. The electric vehicle drive of claim 14, wherein the terminal assembly is configured to output three phase AC power from the power converter circuit.

22. The electric vehicle drive of claim 21, wherein the terminal assembly includes two DC input power conductors disposed intermediate respective output AC power conductors.

23. The electric vehicle drive of claim 14, wherein the support is a fluid cooled support and is adapted to extract heat from the power converter circuit, the energy storage or conditioning circuit and the terminal assembly during operation.

24. The electric vehicle drive of claim 14, wherein the terminal assembly is removably secured to the support.

25. An electric drive for a vehicle at least partially propelled by an electric motor, the drive comprising:

a vehicle drive train;

a power converter assembly operatively coupled to the drive train, the assembly comprising;

a thermal support having first and second sides and configured to receive and to circulate a coolant stream;

a terminal assembly including DC input terminals for receiving DC input power and AC output terminals for transmitting AC output power;

a control circuit;

a drive circuit supported by the thermal support and coupled to the control circuit to receive control signals from the control circuit;

a power converter circuit coupled to the drive circuit and to the DC and AC terminals, the inverter circuit being configured to convert the DC power to controlled frequency AC output power based upon the drive signals; and

an energy storage or conditioning circuit coupled to the DC input terminals and to the power converter circuit via the terminal assembly;

wherein the power converter circuit is supported on the first side of the thermal support and the energy storage or conditioning circuit is supported on the second side of the thermal support, whereby the coolant stream extracts heat from the substrate and the capacitor circuit during operation of the converter circuit.

26. The electric vehicle drive of claim 25, wherein the power converter circuit comprises an inverter circuit.

27. The electric vehicle drive of claim 25, wherein the power converter circuit comprises a matrix converter.

28. The electric vehicle drive of claim 25, wherein the support at least partially defines a reference plane at a desired electrical potential, and wherein the terminal assembly includes an body at the reference desired electrical potential.

29. The electric vehicle drive of claim 25, wherein the support is a single-piece support.

30. The electric vehicle drive of claim 25, wherein the support is a multi-piece support.

31. The electric vehicle drive of claim 25, wherein the energy storage or conditioning circuit includes a capacitor bank.

32. The electric vehicle drive of claim 25, wherein the terminal assembly is configured to output three phase AC power from the power converter circuit.

33. The electric vehicle drive of claim 25, wherein the terminal assembly includes two DC input power conductors disposed intermediate respective output AC power conductors.

34. The electric vehicle drive of claim 25, wherein the support is a fluid cooled support and is adapted to extract heat from the power converter circuit, the energy storage or conditioning circuit and the terminal assembly during operation.

35. The electric vehicle drive of claim 25, wherein the terminal assembly is removably secured to the support.