JP5950246B2 - Reactor - Google Patents

Description

  The present invention relates to a reactor used for a converter of an electric vehicle or a hybrid car.

  In recent years, against the background of environmental problems and the like, hybrid vehicles have rapidly spread and the development of electric vehicles and the like has been promoted. Unlike a conventional internal combustion engine such as a gasoline engine, these hybrid vehicles and electric vehicles are provided with an electric motor drive system.

  Such an electric motor drive system includes a high voltage battery of about 300V, a power control unit (PCU), and a motor, and is connected by a harness.

  The PCU includes various types of sensors such as a boost converter that boosts the voltage to about 600 V, an inverter that drives the motor, a controller, internal connections, and a current sensor. The step-up converter unit includes a switching semiconductor element, a reactor including an annular core made of a magnetic material, and a coil wound with a winding, and a capacitor. In consideration of the fact that a current of 200 to 300 A flows at the peak for the internal wiring, a metal wiring (bus bar) is used and a current sensor for monitoring the current state is attached (Patent Document 1). The current sensor includes a substrate, a Hall element, and a magnetic flux collecting core.

  The voltage of the high-voltage battery boosted from about 300 V to about 600 V using the boost converter is controlled through the inverter, so that the motor is driven.

JP 2010-279150 A

  As described above, various parts are incorporated for driving the motor. However, in a vehicle, since it is necessary to pack many parts in a limited space, downsizing and weight reduction of parts are strongly desired. .

  Then, this invention makes it a subject to provide the product in which size reduction and weight reduction were achieved about the reactor.

As a result of diligent research, the present inventor has found that the above problems can be solved by an invention based on the following technology, and has completed the present invention. Hereinafter, techniques related to the present invention will be described.

The first technique related to the present invention is:
A pair of center cores arranged in parallel and facing each other, each having a coil wound with a winding;
A reactor including a pair of side cores arranged in parallel opposite to each other at both ends of the pair of center cores,
The reactor is characterized in that current measuring means for measuring a current flowing through the reactor using a leakage magnetic flux of the reactor is installed on an outer peripheral surface of the reactor.

  The inventor paid attention to leakage magnetic flux generated on the outer peripheral surface of the reactor from the coil constituting the reactor during energization. That is, when energized, the reactor forms a main magnetic path in the center core from one side core to the other side core, and at the same time, generates a leakage magnetic flux on the outer peripheral surface of the reactor. As a result of the measurement, it was confirmed that the magnetic flux density of the leakage magnetic flux changes in proportion to the energization amount.

  For this reason, the current flowing through the reactor can be detected with high accuracy by installing the current measuring means (current sensor) at an appropriate position on the outer peripheral surface of the reactor.

In the present technology , since the current measuring means (current sensor) is formed integrally with the reactor, the volume of the reactor itself is not substantially increased, and an increase in the volume or weight of the PCU is suppressed. be able to. Further, since it is not necessary to separately incorporate a bus bar or a current sensor after incorporating the reactor into the converter or the like, the process can be simplified and the number of parts constituting the PCU can be reduced.

The second technique related to the present invention is:
The reactor according to the first technique , wherein the current measuring unit uses a Hall element or a Hall IC.

  As current measuring means (current sensor), there are various current sensors such as a current sensor using a Hall effect, a current sensor using a current transformer, and a current sensor using a shunt resistor. The use of a Hall IC is preferable from the viewpoints of insulation, detection of a DC component, detection accuracy, and the like.

The third technique related to the present invention is:
The reactor according to the first technique or the second technique , wherein the current measuring means is arranged along the center core.

  Even in the outer peripheral surface of the reactor, near the center core where the coil is wound, the magnetic flux density of the leakage flux is high, so when current measuring means is arranged along the center core, the current flowing through the reactor with higher accuracy Can be detected.

The fourth technique related to the present invention is:
The reactor according to the third technique , wherein the current measuring means is disposed along an upper surface or a lower surface of the center core.

  When arranging the current measuring means along the center core, the current is measured along the upper surface (upper surface) or lower surface (lower surface) of the surface formed by the side core and the center core, or the side surface. Whether to arrange the means may be determined in consideration of design restrictions or the like, but considering the ease of arrangement, it is preferable to arrange the means along the upper surface or the lower surface of the center core.

The fifth technique related to the present invention is:
The reactor according to the third technique , wherein the current measuring means is disposed along a side surface of the center core.

  By disposing the current measuring means along the side surface of the center core, the thickness of the reactor can be reduced.

The sixth technique related to the present invention is:
Each of the pair of center cores is composed of two or more middle cores,
It said current measuring means, a reactor according to the third one to one fifth technical no technology characterized by being arranged along a Midorukoa closer to the side core.

  In general, the pair of center cores constituting the reactor are each composed of two or more middle cores. The leakage magnetic flux generated during energization has a higher magnetic flux density in the middle core closer to the side core. For this reason, when the current measuring means is arranged along the middle core close to the side core, the current flowing through the reactor can be detected with higher accuracy.

The seventh technique related to the present invention is:
Center of the current measuring means, any one of the third technique to sixth technical magnetic flux density of the leakage magnetic flux is characterized in that it is arranged in the region of at least 50% of the peak value It is a reactor as described in.

And the 8th technique relevant to this invention is:
Center of the current measuring means, any one of the third technique to sixth technical magnetic flux density of the leakage magnetic flux is characterized in that it is arranged in the region is at least 70% of the peak value It is a reactor as described in.

  When arranging the current measuring means along the middle core close to the side core, the magnetic flux density of the leakage magnetic flux changes depending on the position on the outer peripheral surface of the middle core, and by arranging the current measuring means in a region showing a high magnetic flux density, The current flowing through the reactor can be detected with higher accuracy. According to the results of experiments conducted by the present inventor, it is possible to reliably detect the current if it is in the region of 50% or more of the peak magnetic flux density, and more accurately detect the current in the region of 70% or more. It becomes possible.

The ninth technique related to the present invention is:
The central portion of the current measuring means is
On the upper surface of the middle core close to the side core,
When the length of the upper surface of the middle core is L and the width is W, it is within a range of 0.2 L to 0.6 L from the end on the side core side of the middle core and 0 to 0.7 W from the end on the outer peripheral surface side. The reactor according to the sixth technique , which is arranged.

  Next, the present inventor details the magnetic flux distribution of the leakage magnetic flux on the upper surface of the reactor, in which each of the generally used center cores is composed of three middle cores (3 / row × 2 rows). The above-described “region where the magnetic flux density of the leakage magnetic flux is 70% or more of the peak value” was specifically obtained.

  FIG. 7 is a view of the core 7 as viewed from above. Each center core 71 is composed of three middle cores 71 a and both ends are sandwiched between side cores 73. W is the width of the middle core 71a, and L is the length.

  As a result of the experiment, a region defined by 0.2 L to 0.6 L from the end on the side core 73 side of the middle core (side core 73 side) 71 a and 0 to 0.7 W from the outer end is a magnetic flux of leakage magnetic flux. It is an area where the density is 70% or more of the peak value, and this position was found to be suitable as a position where the central portion of the current measuring means (current sensor) is arranged.

The tenth technique related to the present invention is:
One of the side cores is provided with a rewinding portion for winding the coil from one center core to the other center core,
The reactor according to the first technique or the second technique , wherein the current measuring means is installed in an upper part of the winding-up part.

  When current measuring means is installed on the upper part of the rewinding part that rewinds the coil from one center core to the other center core, in addition to the leakage magnetic flux described above, the current flowing through the reactor is detected using the magnetic flux generated in the rewinding part. Therefore, the current flowing through the reactor can be detected with higher accuracy.

The eleventh technology related to the present invention is:
The center core, the side core and said current measuring means is a reactor according to any one of the first techniques to tenth technical, characterized in that it is fixed by the molding resin processing.

  By processing the mold resin, all of the center core, the side core, the current measuring means (current sensor) and the like can be fixed at once, and since the resin processing is performed, an increase in the weight of the reactor can be suppressed.

The present invention has been made on the basis of the above-described technologies, and the invention according to claim 1
A pair of center cores arranged in parallel and facing each other, each having a coil wound with a winding;
  A pair of side cores arranged in parallel opposite to each other at both ends of the pair of center cores;
A reactor with
  Current measuring means for measuring the current flowing through the reactor using the leakage magnetic flux of the reactor is installed on the outer peripheral surface of the reactor,
  The current measuring means is disposed along the center core;
  The central portion of the current measuring means is disposed in a region where the magnetic flux density of the leakage magnetic flux is 50% or more of the peak value.
It is a reactor characterized by this.

The invention according to claim 2
  A pair of center cores arranged in parallel and facing each other, each having a coil wound with a winding;
A pair of side cores arranged in parallel opposite to each other at both ends of the pair of center cores;
A reactor with
Current measuring means for measuring the current flowing through the reactor using the leakage magnetic flux of the reactor is installed on the outer peripheral surface of the reactor,
The current measuring means is disposed along the center core;
The central part of the current measuring means is arranged in a region where the magnetic flux density of the leakage magnetic flux is 70% or more of the peak value.
It is a reactor characterized by this.

The invention according to claim 3
A pair of center cores arranged in parallel and facing each other, each having a coil wound with a winding;
A pair of side cores arranged in parallel opposite to each other at both ends of the pair of center cores;
A reactor with
Current measuring means for measuring the current flowing through the reactor using the leakage magnetic flux of the reactor is installed on the outer peripheral surface of the reactor,
The current measuring means is disposed along the center core;
Each of the pair of center cores is composed of two or more middle cores,
The current measuring means is disposed along a middle core close to the side core;
The central portion of the current measuring means is
On the upper surface of the middle core close to the side core,
When the length of the upper surface of the middle core is L and the width is W, it is within a range of 0.2 L to 0.6 L from the end on the side core side of the middle core and 0 to 0.7 W from the end on the outer peripheral surface side. Arranged
It is a reactor characterized by this.

The invention according to claim 4
A pair of center cores arranged in parallel and facing each other, each having a coil wound with a winding;
A pair of side cores arranged in parallel opposite to each other at both ends of the pair of center cores;
A reactor with
Current measuring means for measuring the current flowing through the reactor using the leakage magnetic flux of the reactor is installed on the outer peripheral surface of the reactor,
One of the side cores is provided with a rewinding portion for winding the coil from one center core to the other center core,
The current measuring means is installed on the upper part of the winding part.
It is a reactor characterized by this.

The invention according to claim 5
The reactor according to any one of claims 1 to 4, wherein the current measuring means uses a Hall element or a Hall IC.

The invention according to claim 6
The reactor according to any one of claims 1 to 3, wherein the current measuring means is disposed along an upper surface or a lower surface of the center core.

The invention according to claim 7
The reactor according to any one of claims 1 to 3, wherein the current measuring means is arranged along a side surface of the center core.

Further, the invention according to claim 8 is
Each of the pair of center cores is composed of two or more middle cores,
The reactor according to any one of claims 1, 2, and 7, wherein the current measuring means is disposed along a middle core close to the side core.

The invention according to claim 9 is
The reactor according to any one of claims 1 to 8, wherein the center core, the side core, and the current measuring unit are fixed by molding resin processing.

  In the present invention, it is possible to provide a reactor that is further reduced in size and weight.

It is a perspective view which shows typically the reactor in one embodiment of this invention. It is a figure explaining the measurement of the magnetic flux density of the reactor in one embodiment of this invention. It is a figure which shows the result of having measured the output voltage of Hall IC in one embodiment of this invention. It is a figure which shows the result of having measured the output voltage of Hall IC in one embodiment of this invention in three dimensions. It is a figure explaining the determination method of the preferable arrangement position of Hall IC in the Y direction of one embodiment of this invention. It is a figure explaining the determination method of the preferable arrangement position of Hall IC in the X direction of one embodiment of this invention. It is a figure explaining the preferable arrangement position of Hall IC of one embodiment of the present invention.

  Hereinafter, the present invention will be described based on embodiments.

1. Configuration of Reactor FIG. 1 is a perspective view schematically showing a reactor in the present embodiment. In FIG. 1, 1 is a reactor, 11 is a center core, 12 is a coil, 13 is a side core, 14 is a current measuring unit, 14a is a Hall IC (current measuring means), and 14b is a substrate. In the present embodiment, the reactor 1 is manufactured in a size of (vertical) 80 × (horizontal) 120 × (height) 60 mm.

  As shown in FIG. 1, the reactor 1 is arranged in parallel to face each other, and a pair of center cores 11 each having a plurality of coils 12 each wound with a winding, and both ends of the center core 11, And a pair of side cores 13 arranged in parallel to face each other.

  Further, a current measuring unit 14 is disposed near the side core 13 along the upper surface of the center core 11, and the current measuring unit 14 is configured by providing a Hall IC 14a on a substrate 14b. Thus, by providing the Hall IC 14a along the center core 11, the leakage magnetic flux generated on the outer peripheral surface of the reactor can be detected, and the current flowing through the reactor 1 can be accurately measured.

  Note that peripheral components such as a chip resistor and a chip capacitor may be mounted on the substrate 14b. The substrate 14b is preferably fixed using an epoxy adhesive or the like. Thereby, since the board | substrate 14b can be hold | maintained stably, the motion of Hall IC14a or a lead (not shown) is controlled and more stable detection is performed.

  A Hall element may be used instead of the Hall IC. In FIG. 1, the Hall IC 14a is disposed along the top surface of the center core, but may be disposed along the side surface.

  The center core 11, the side core 13, and the current measuring unit 14 are fixed by molding resin (not shown) processing.

  Each of the pair of center cores 11 is composed of two or more middle cores (see FIG. 7) as described above. For example, a configuration of 2 / row × 2 rows, 3 / row × 2 rows, 4 pieces / Row × 2 row configuration or more, and as described above, the type of 3 / row × 2 row configuration is widely used. The width (W), length (L) (see FIG. 7), and height (thickness) of each middle core are, for example, about 24 mm, 20 mm, and 25 mm, respectively.

  Further, a gap material having a predetermined thickness (about 1.5 to 2.5 mm) is disposed between the center core 11, the side core 13, and the adjacent middle cores, and is thermally cured using an epoxy resin adhesive or the like. Thus, they are joined together.

  When winding the winding, a bobbin (not shown) formed from PBT (polybutylene terephthalate) resin or the like is usually arranged around the center core 11 in advance.

  As the forming material of each center core 11 and side core 13, a soft magnetic material obtained by compression-molding iron powder subjected to insulation coating is preferably used. As the gap material, a PBT resin, a PA (polyamide) resin, or a resin material mixed with magnetic powder is preferably used.

  In addition, as a winding forming the coil, a rectangular enameled wire (copper, which is a conductor, coated with a film of polyimide resin or the like (thickness: about 30 to 40 μm) (size is, for example, 4.5 × 1.7 mm)) Etc. are preferably used.

2. Area in which Hall IC is arranged The center of Hall IC 14a is preferably arranged in an area where the magnetic flux density of the leakage magnetic flux is high. Specifically, the hall IC 14a is arranged in an area of 50% or more of the measured peak value. It is preferable. By arranging the Hall IC 14a in this region, it is possible to reliably detect the current from the magnetic flux density of the leakage magnetic flux, and it is possible to detect the current with higher accuracy in the region of 70% or more.

  Hereinafter, a setting method of this area will be described in detail by taking a reactor including a center core composed of 3 cores × 2 rows of middle cores as an example.

(1) Measurement of magnetic flux density of leakage magnetic flux The specific area | region which arrange | positions Hall IC is set based on the result of having measured the magnetic flux density of the leakage magnetic flux in a reactor in the X direction and the Y direction of a reactor. 2A and 2B are diagrams for explaining the measurement of the magnetic flux density of the reactor in the present embodiment. FIG. 2A is a diagram showing a measurement result, and FIG. 2B is a diagram for explaining a measurement method. In the present embodiment, the magnetic flux distribution is obtained by setting the coordinates in the X direction and the Y direction along the upper surface of the reactor and measuring the magnetic flux density at each coordinate.

A. Coordinate setting X direction: From the outer peripheral side end face of one center core toward the outer peripheral side end face of the other center core, both ends are divided into X (0) and X (50), respectively. The coordinates of 0) to X (50) were set. In FIG. 2B, only the X coordinate in the lower center core, that is, X (25) to X (50) is shown.

  Y direction: From left to right of the center core shown in FIG. 2 (b), the left 5mm portion of the leftmost middle core is Y (0) and the right 5mm portion of the rightmost middle core is Y As (80), the interval was equally divided into 80, and the coordinates of Y (0) to (80) were set.

B. Measurement of the Hall IC output voltage A current of 30 A is passed through the coil, and the X coordinate is changed by 5 from X (0) to X (50), while the Hall IC (Melexis, IC90288) is moved in the Y direction Were scanned from Y (0) to Y (75), and the output voltage of the Hall IC at each coordinate was measured (offset value: 2.465V). The measurement results are shown in Table 1, and based on these results, the output voltage of the Hall IC in the Y direction at each X coordinate is shown in FIG. 3, and a three-dimensional display diagram with each X coordinate and each Y coordinate as the bottom is shown. 4 shows. In Table 1, the vertical direction is the X coordinate and the horizontal direction is the Y coordinate.

  From the results shown in FIGS. 3 and 4, it can be seen that the output voltage of the Hall IC differs depending on the measurement position.

C. Calculation of magnetic flux density Next, the magnetic flux density B (T) at each coordinate at 200 A was obtained from the sensitivity value of the Hall IC using the above measurement result. Table 2 shows the calculation results. In Table 2, the vertical direction is the X coordinate and the horizontal direction is the Y coordinate.

  The diagram shown in FIG. 2A is obtained by plotting the measured values at one center core, that is, measured values at X (25) to X (50), from the data in Table 2 above.

  From the result shown in FIG. 2A, in the X direction, X (40) to X (50) close to the outer peripheral surface of the reactor are compared with X (25) to X (30) close to the central axis of the reactor. The direction shows a larger peak, and it can be seen that the outer peripheral surface of the center core has a higher magnetic flux density.

  Moreover, about Y direction, the big peak is shown by Y (10) and Y (70) near a side core, and it turns out that a magnetic flux density is high in the location near a side core.

  Thus, the high magnetic flux density is observed near the outer peripheral surface of the reactor and the side core because the magnetic flux cancels out on the center side.

(2) Determination of area where Hall IC is arranged Next, a preferable area where Hall IC is arranged was obtained based on the measurement result. Specifically, as described above, since it is possible to detect the current with higher accuracy in the region of 70% or more of the peak value, each direction in the X direction and the Y direction of the portion where the peak value is obtained. A region where a magnetic flux density of 70% or more of the peak value was obtained was obtained.

  FIG. 5 is a diagram for explaining a method for determining a preferred arrangement position of the Hall IC in the Y direction according to the present embodiment. FIG. 5A shows the magnetic flux density at X (50) where the maximum peak is obtained in the X direction. It is a figure which shows the distribution condition to a Y direction, (b) is a figure which shows the result of having calculated | required the range A of the Y direction used as 70% or more of the said peak value. The right figure of (b) shows the peak of (a) upside down.

  From (b), the preferable length of the region A in the Y direction is 0.4 L with respect to the length L of the middle core near the side core, and the center of A is at a position 0.4 L from the end of the side core. Thus, it can be seen that the preferred region in the Y direction is in the region of 0.2L to 0.6L from the end of the side core. The same applies to the peak of Y (70) on the right side of (a), and a region of 0.2 L to 0.6 L is preferable from the end of the side core.

  FIG. 6 is a diagram for explaining a method of determining a preferred arrangement position of the Hall IC in the X direction according to the present embodiment, where (a) shows the magnetic flux density in Y (10) where the maximum peak is obtained in the Y direction. (B) is a figure which shows the result of having calculated | required the range B of the Y direction used as 70% or more of the said peak value.

  From (b), since the preferable region B in the X direction is X (34) to X (50), the preferable region in the X direction is about 0 with respect to the width W of the middle core from the outer peripheral surface side of the center core. It can be seen that the area is up to 7W.

  While the present invention has been described based on the embodiments, the present invention is not limited to the above embodiments. Various modifications can be made to the above-described embodiments within the same and equivalent scope as the present invention.

1 Reactor 7 Core 11, 71 Center Core 12 Coil 13, 73 Side Core 14 Current Measurement Unit 14a Hall IC
14b Substrate 71a Middle core A Range in the Y direction B Range in the X direction L Length of the middle core W Width of the middle core

Claims (9)

A pair of center cores arranged in parallel and facing each other, each having a coil wound with a winding;
A reactor including a pair of side cores arranged in parallel opposite to each other at both ends of the pair of center cores,
Current measuring means for measuring the current flowing through the reactor using the leakage magnetic flux of the reactor is installed on the outer peripheral surface of the reactor ,
The current measuring means is disposed along the center core;
The reactor , wherein a central portion of the current measuring means is disposed in a region where the magnetic flux density of the leakage magnetic flux is 50% or more of a peak value . A pair of center cores arranged in parallel and facing each other, each having a coil wound with a winding;
A pair of side cores arranged in parallel opposite to each other at both ends of the pair of center cores;
A reactor with
Current measuring means for measuring the current flowing through the reactor using the leakage magnetic flux of the reactor is installed on the outer peripheral surface of the reactor,
The current measuring means is disposed along the center core;
The current center of the measuring means, the leakage magnetic flux of the magnetic flux density characteristics and to Brighter Akutoru the <br/> that is disposed in a region of 70% or more of the peak value. A pair of center cores arranged in parallel and facing each other, each having a coil wound with a winding;
A pair of side cores arranged in parallel opposite to each other at both ends of the pair of center cores;
A reactor with
Current measuring means for measuring the current flowing through the reactor using the leakage magnetic flux of the reactor is installed on the outer peripheral surface of the reactor,
The current measuring means is disposed along the center core;
Each of the pair of center cores is composed of two or more middle cores,
The current measuring means is disposed along a middle core close to the side core;
The central portion of the current measuring means is
On the upper surface of the middle core close to the side core,
When the length of the upper surface of the middle core is L and the width is W, it is within a range of 0.2 L to 0.6 L from the end on the side core side of the middle core and 0 to 0.7 W from the end on the outer peripheral surface side. features and to Brighter Akutoru the <br/> be disposed. A pair of center cores arranged in parallel and facing each other, each having a coil wound with a winding;
A pair of side cores arranged in parallel opposite to each other at both ends of the pair of center cores;
A reactor with
Current measuring means for measuring the current flowing through the reactor using the leakage magnetic flux of the reactor is installed on the outer peripheral surface of the reactor,
One of the side cores is provided with a rewinding portion for winding the coil from one center core to the other center core,
It said current measuring means, features and to Brighter Akutoru the <br/> that is installed in the upper portion of the rewinding section. The reactor according to any one of claims 1 to 4, wherein the current measuring means uses a Hall element or a Hall IC. The reactor according to any one of claims 1 to 3, wherein the current measuring means is disposed along an upper surface or a lower surface of the center core. The reactor according to any one of claims 1 to 3, wherein the current measuring means is disposed along a side surface of the center core. Each of the pair of center cores is composed of two or more middle cores,
It said current measuring means, according to claim 1, characterized in that disposed along the Midorukoa closer to the side core, reactor according to any one of claims 2 and 7. The reactor according to any one of claims 1 to 8 , wherein the center core, the side core, and the current measuring unit are fixed by molding resin processing.

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