Motor controller

Abstract

The invention relates to a motor controller, and belongs to the field of electric vehicle manufacturing. Comprising a motor control device which comprises a capacitor, a high-voltage input connector and a shielding magnetic ring; a containing cavity is formed in the motor controller shell, and the capacitor is installed in the containing cavity; the top of the installation box is communicated with the containing cavity, an installation opening is formed in the bottom of the installation box, the high-voltage input connector is connected to the bottom of the installation box, the shielding magnetic ring is installed in the installation box, and the shielding magnetic ring and the high-voltage input connector are connected through the installation opening. Under the condition that the capacity of the motor controller shell is limited, the layout and the installation mode of each component are optimized, the space is expanded from the bottom of the motor controller shell, and the shielding magnetic ring is installed, so that the size of the motor controller shell is reduced, and the assembly space utilization rate in an electric automobile is improved.

Description

Technical Field

[0001] This application relates to the field of electric vehicle manufacturing, and particularly to a motor controller. Background Art

[0002] The controller is a core control component in an electric vehicle and plays a crucial role in it. The controller housing of a single-motor controller is generally a square box, with a whole cover plate on the top. The periphery of the cover plate is connected to the housing by bolts. The internal accommodation cavity houses an IGBT module, a PCB board assembly, a DC bus capacitor, a three-phase copper busbar terminal block, a current sensor, a shielding magnetic ring, etc. Each component is installed from top to bottom, and high- and low-voltage connectors such as high-voltage output and resolver are provided on the side. During installation, it is still installed through the opening of the upper cover plate.

[0003] With the increase in the driving range of electric vehicles and the need for a high-voltage architecture platform, the voltage that the bus capacitor needs to support is getting higher and higher. It is required that while the high-voltage input copper busbar of the bus capacitor is equipped with a shielding magnetic ring, the DC high-voltage input connector terminal is also equipped with a shielding magnetic ring. Therefore, for the capacitor module installation part of the motor controller housing, when installing from top to bottom, the housing requires a relatively large accommodation and installation space. At this time, the horizontally extended volume of the housing becomes larger, increasing the horizontal plane volume of the single-motor controller, which is not conducive to the optimization of the overall machine assembly space. Summary of the Invention

[0004] Embodiments of this application provide a motor controller to solve the problem in the related art that with the increase in the driving range of electric vehicles, for the capacitor module installation part of the motor controller housing, when installing from top to bottom, the housing also requires an increased accommodation and installation space, resulting in an increase in the horizontally extended volume of the housing, increasing the horizontal plane volume of the single-motor controller, which is not conducive to the optimization of the overall machine assembly space.

[0005] Embodiments of this application provide a motor controller, including: a motor control device, which includes a capacitor, a high-voltage input connector, and a shielding magnetic ring; a motor controller housing, with an accommodation cavity formed inside, the capacitor is installed in the accommodation cavity; an installation box, the top of which communicates with the accommodation cavity, the bottom of the installation box is provided with an installation opening, the high-voltage input connector is connected to the bottom of the installation box, and the shielding magnetic ring is installed in the installation box, and the shielding magnetic ring and the high-voltage input connector are connected through the installation opening.

[0006] In some embodiments, one side of the installation box is provided with an operation window, and a window cover plate is connected to the installation box at the operation window.

[0007] In some embodiments, the motor control device further includes: an IGBT module, which is installed in the accommodation cavity, and the capacitor is connected to the lead copper row of the IGBT module; a three-phase copper row terminal block, which is installed in the accommodation cavity and is electrically connected to the IGBT module; a three-phase lead copper row, which is installed in the accommodation cavity and is connected to the three-phase copper row terminal block; a high-voltage output connector, which is installed on one side of the motor controller housing, and the high-voltage output connector passes through the motor controller housing and is connected to the three-phase lead copper row.

[0008] In some embodiments, a PCB board is provided on the IGBT module, the capacitor, and the three-phase copper row connection seat in the accommodation cavity. A current sensor and a resolver connector are provided on the PCB board. A resolver signal plug is further provided on the motor controller housing, and the resolver signal plug is electrically connected to the resolver connector.

[0009] In some embodiments, a low-voltage connector is further provided in the accommodation cavity.

[0010] In some embodiments, a cooling water channel is further provided on the motor controller housing, and a water channel cover plate is further provided on the cooling water channel in the accommodation cavity.

[0011] In some embodiments, a waterproof and breathable valve is provided on the motor controller housing.

[0012] In some embodiments, a metal shielding cover is provided on the three-phase copper row terminal block.

[0013] In some embodiments, a capacitor mounting cylindrical surface is provided in the accommodation cavity.

[0014] In some embodiments, a window sealing ring is provided at the operation window

[0015] The beneficial effects brought by the technical solution provided by this application include:

[0016] The embodiment of this application provides a motor controller. When the cruising range of an electric vehicle increases, according to the requirements of the high-voltage architecture platform, a large-voltage support is provided for the capacitor. Therefore, while the high-voltage input copper row of the capacitor itself is provided with a shielding magnetic ring, the DC high-voltage input connector terminal is also provided with a shielding magnetic ring. Therefore, by providing an installation box at the bottom of the motor controller housing, the shielding magnetic ring is connected in the installation box, and an installation opening is provided at the bottom of the installation box. The shielding magnetic ring is connected to the high-voltage input connector from the installation opening, and the high-voltage connector is fixed at the bottom of the installation box, so as to extend and expand the assembly space of the whole machine at the bottom of the motor controller housing, which is beneficial to reducing the horizontal volume of the whole machine, and the structures of all components are compact. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] To more clearly illustrate the technical solutions in the embodiments of the present application, the following will briefly introduce the accompanying drawings required for the description of the embodiments. Obviously, the accompanying drawings in the following description are only some embodiments of the present application. For those of ordinary skill in the art, without creative efforts, other accompanying drawings can be obtained based on these drawings.

[0018] Figure 1 It is an exploded structure schematic diagram showing the overall structure provided by the embodiment of the present application;

[0019] Figure 2 It is a structure schematic diagram showing the PCB board provided by the embodiment of the present application;

[0020] Figure 3 It is a structure schematic diagram showing the installation box and the installation port provided by the embodiment of the present application;

[0021] Figure 4 It is a schematic diagram showing the internal structure of the accommodation cavity provided by the embodiment of the present application.

[0022] Reference numerals:

[0023] 1, motor control device; 10, capacitor; 100, capacitor installation port; 11, high-voltage input connector; 12, shielding magnetic ring; 13, IGBT module; 130, three-phase copper bar; 14, three-phase copper bar wiring seat; 140, metal shielding cover; 15, three-phase lead-out copper bar; 16, high-voltage output connector; 160, connection port; 2, motor controller housing; 20, accommodation cavity; 21, housing cover plate; 22, housing sealing ring; 23, installation surface; 3, installation box; 30, installation port; 31, operation window; 310, window cover plate; 311, window sealing ring; 4, PCB board; 40, current sensor; 41, resolver connector; 5, resolver signal plug-in; 6, low-voltage connector; 70, water inlet pipe; 71, water outlet pipe; 72, water channel cover plate; 8, waterproof breathable valve; 9, capacitor installation cylindrical surface. Detailed implementation manners

[0024] To make the objectives, technical solutions, and advantages of the embodiments of the present application clearer, the following will clearly and completely describe the technical solutions in the embodiments of the present application with reference to the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are some, but not all, of the embodiments of the present application. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present application without creative efforts fall within the scope of protection of the present application.

[0025] The embodiment of the present application provides a motor controller, which can solve the following problems: with the increase in the driving range of electric vehicles, for the installation part of the capacitor module on the motor controller housing, when installing from top to bottom, the housing needs to accommodate and install more space, resulting in an increase in the horizontally extended volume of the housing, increasing the horizontal plane volume of a single motor controller, which is not conducive to optimizing the assembly space of the whole machine.

[0026] As shown in Figures 1 to 4 the embodiment of the present application provides a motor controller, including a motor control device 1, a motor controller housing 2, and an installation box 3. Among them, the provided motor control device 1 includes a capacitor 10, a high-voltage input connector 11, and a shielding magnetic ring 12; the provided capacitor 10 is adapted for use in electric vehicles with a large driving range; the high-voltage input connector 11 is set as a two-hole high-voltage connector, and the two holes are divided into positive and negative interfaces; the shielding magnetic ring 12 will generate magnetic resistance under the action of an external electromagnetic field, and suppress electromagnetic interference through its unique magnetic resistance, magnetic shielding, and magnetic saturation characteristics, as well as its impedance characteristics that change with frequency.

[0027] An accommodation cavity 20 is formed inside the provided motor controller housing 2, and a capacitor installation port 100 is further provided on the bottom wall of the accommodation cavity 20. The capacitor 10 is installed in the accommodation cavity 20 through the capacitor installation port 100; the top of the installation box 3 communicates with the accommodation cavity 20 through the capacitor installation port 100. Then, an installation port 30 is provided at the bottom of the installation box 3. The high-voltage input connector 11 is connected to the bottom of the installation box 3, and the shielding magnetic ring 12 is installed in the installation box 3. Finally, the shielding magnetic ring 12 and the high-voltage input connector 11 are connected through the installation port 30.

[0028] With the increase in the driving range of electric vehicles, the demand for high-voltage architecture platforms has become increasingly prominent. This is mainly because the high-voltage platform can significantly improve the charging efficiency and driving range of electric vehicles, thus alleviating users' "range anxiety" and "charging anxiety". In this process, as an important part of the high-voltage circuit of electric vehicles, the capacitor 10 needs to support a higher voltage. The high-voltage input connector 11 with a shielding magnetic ring 12 can suppress the propagation of electromagnetic interference signals, ensuring the stability and safety of electric vehicles in a high-voltage working environment. In the present application, by assembling each component from top to bottom directly above the motor controller housing 2, the high-voltage input connector 11 is led out from the bottom of the motor controller housing 2, and the shielding magnetic ring 12 is installed in the installation box 3, converting the volume that needs to extend horizontally into a vertical volume, which is beneficial to reducing the volume of the motor controller housing 2 and optimizing the assembly space of the whole machine.

[0029] In the present application, a housing cover 21 is also connected to the top of the accommodating chamber 20, and a housing seal ring 22 is provided on the top of the accommodating chamber 20. The housing seal ring 22 is arranged around the motor controller housing 2. The housing seal ring 22 improves the sealing of the motor controller housing 2, avoids rainwater leakage from the top of the accommodating chamber 20, and ensures the stability of the motor control device. When in use, the housing cover 21 is opened, and the capacitor 10 is assembled from the top of the accommodating chamber 20, which is convenient to use.

[0030] In the present application, in order to facilitate the installation of the shielding magnetic ring 12, an operation window 31 is provided on one side of the installation box 3, and the installation and removal of the shielding magnetic ring 12 can be completed quickly from the operation window 31, which is very convenient. In addition, a window cover 310 is connected to the operation window 31 on the installation box 3, and the window cover 310 protects the shielding magnetic ring 12 from rainwater and other debris, and a window sealing ring 311 is provided at the operation window 31. Further, under the action of the window sealing ring 311, the sealing between the window cover 310 and the operation window 31 is good, the sealing effect is improved, and the rainwater rust in the installation box 3 is avoided.

[0031] In the present application, in order to facilitate the installation of the capacitor 10, a capacitor mounting cylinder 9 is also provided in the accommodating cavity 20. The capacitor mounting cylinder 9 can be divided into a capacitor 10 plane mounting cylinder and a capacitor 10 side mounting cylinder, wherein the capacitor 10 plane mounting cylinder is arranged on the side wall of the capacitor mounting opening 100, and the capacitor 10 side mounting cylinder is arranged on the side wall of the mounting box 3, and the capacitor mounting cylinder 9 makes the assembly and maintenance of the motor controller more convenient.

[0032] In addition, a mounting surface 23 is provided on the side wall of the motor controller housing 2, and the single motor controller can be mounted and fixed on the mounting surface 23 by means of bolts, so that the structure is simple and reliable.

[0033] In the present application, the motor control device 1 also includes: an IGBT module 13, a three-phase copper busbar terminal block 14, a three-phase lead-out copper busbar 15, and a high-voltage output connector 16. The IGBT module 13 is installed in the accommodating cavity 20 and assembled close to the capacitor 10, and the capacitor 10 is connected to the lead-out copper busbar of the IGBT module 13; the three-phase copper busbar terminal block 14 is also installed in the accommodating cavity 20 and electrically connected to the IGBT module 13; the three-phase lead-out copper busbar 15 is installed in the accommodating cavity 20 and connected to the three-phase copper busbar terminal block 14; the high-voltage output connector 16 is installed on one side of the motor controller housing 2, and the high-voltage output connector 16 is connected to the three-phase lead-out copper busbar 15 through the connection port 160 by opening a connection port 160 on one side of the motor controller housing 2.

[0034] The set IGBT module 13 is a modular electronic component integrating functions such as multiple IGBT chips, drive circuits, and protection circuits. It has the advantages of low on-resistance and high switching speed, and also has high voltage tolerance and strong current-carrying capacity. The capacitor 10 is connected to the lead copper bar of the IGBT module 13, the three-phase copper bar terminal block 14 is electrically connected to the IGBT module 13, the three-phase lead copper bar 15 is connected to the three-phase copper bar terminal block 14, and the high-voltage output connector 16 is connected to the three-phase lead copper bar 15. The capacitor 10 forms a DC input channel by connecting to the lead copper bar of the IGBT module 13. The IGBT module 13 receives DC power and converts it into AC power to output to the three-phase copper bar terminal block 14. The three-phase copper bar terminal block 14 is an important component for electrical connection and transmission in the motor controller. The three-phase copper bar terminal block 14 can transmit the AC power output by the IGBT module 13 to the motor. Specifically, the three-phase lead copper bar 15 leads out the three-phase power and connects it to the motor. The three-phase copper bar terminal block 14 is electrically connected to the three-phase lead copper bar 15 through the wiring terminals thereon to receive the AC power from the IGBT module 13. At the same time, the three-phase current output by the three-phase lead copper bar 15 can be output by the high-voltage output connector 16, effectively transmitting the power of the three-phase copper bar terminal block 14 to the motor or other components for the motor to use.

[0035] In this application, the three-phase copper bar terminal block 14 is set as the UVW three-phase lead copper bar 15. The three-phase lead copper bar 15 is a key component in the electrical system for connecting three-phase power sources or loads, mainly responsible for transmitting current and voltage to ensure the normal operation of electrical equipment. The UVW three-phase lead copper bar 15 specifically refers to the copper bar used to connect the three-phase power sources or loads of the U phase, V phase, and W phase in the electrical system. It also has the function of transmitting current and voltage, but emphasizes the specific arrangement and connection method between the three phases. In applications such as new energy vehicle motors, the UVW three-phase lead copper bar 15 also plays important roles such as preventing electromagnetic interference and optimizing motor performance.

[0036] In this application, a three-phase copper bar 130 is connected between the three-phase copper bar terminal block 14 and the IGBT module 13. The three-phase copper bar 130, as a key connection component in the electrical system, is responsible for effectively connecting the three-phase copper bar terminal block 14 and the IGBT module 13 together. This connection ensures that current and voltage can be smoothly transmitted between the two, thus meeting the operation requirements of the electrical system. The three-phase copper bar 130 is made of copper material with high conductivity and has a low resistivity. In the electrical system, using the three-phase copper bar 130 to connect the three-phase copper bar terminal block 14 and the IGBT module 13 can effectively reduce the line resistance, thereby reducing the power loss during the line transmission of electrical energy.

[0037] In this application, a PCB board 4 is further provided on the connection seat of the IGBT module 13, the capacitor 10, and the three-phase copper busbar 130 within the accommodation cavity 20. A current sensor 40 and a resolver connector 41 are provided on the PCB board 4. A resolver signal plug-in 5 is also provided on the motor controller housing 2. The resolver signal plug-in 5 is electrically connected to the resolver connector 41 through a wire harness. The resolver signal plug-in 5 can be externally connected to the motor resolver to detect the position and speed of the motor rotor.

[0038] In the motor controller, the PCB board 4 is responsible for signal acquisition, processing, and the implementation of control algorithms. The PCB board 4 is cleverly arranged within the accommodation cavity 20 between the IGBT module 13, the capacitor 10, and the connection seat of the three-phase copper busbar 130. This layout not only helps to reduce space occupancy and improve the integration of the device, but also contributes to optimizing electrical performance and thermal management. The current sensor 40 is used to detect the magnitude and direction of the motor phase current in real time, providing an accurate current feedback signal to the controller. These signals are crucial for achieving precise motor control. The resolver connector 41 can provide accurate position information of the motor rotor. The resolver signal plug-in 5, as an interface between the resolver connector 41 and external devices, is responsible for transmitting the output signal of the resolver connector 41 to the controller or other devices that require these signals, ensuring reliable signal transmission and device interoperability.

[0039] In this application, a metal shielding cover 140 is also provided on the three-phase copper busbar terminal block 14. The metal shielding cover 140 can effectively reduce the interference of external electromagnetic fields on the three-phase copper busbar terminal block 14 and its internal circuit. In a complex electromagnetic environment, external electromagnetic sources may have an adverse impact on the power system through air or wire conduction. The metal shielding cover 140 shields the external electromagnetic field outside through its conductive properties, protecting the internal circuit from interference and ensuring the normal sampling operation of the current sensor 40 integrated on the PCB board 4.

[0040] In this application, a low-voltage connector 6 is also provided within the accommodation cavity 20. The low-voltage connector 6 is connected to the interface of the vehicle's low-voltage power supply and low-voltage signals. In the vehicle's electric drive system, the low-voltage connector 6 is a bridge between the motor controller and the vehicle's low-voltage power supply and signal network. Through the low-voltage connector 6, the motor controller can receive control instructions and power support from the vehicle system and transmit its own operating status and feedback information to the vehicle system. This integration method not only improves the overall performance and reliability of the system, but also facilitates system maintenance and upgrade.

[0041] In this application, a cooling water channel is further provided on the motor controller housing 2, and a water channel cover plate 72 is provided on the cooling water channel within the accommodation cavity 20. The cooling water channel includes a water inlet pipe 70 and a water outlet pipe 71. The cooling water channel is an important part of the cooling system in the motor controller. The coolant (such as water or coolant) circulating through the water inlet pipe 70 and the water outlet pipe 71 absorbs and carries away the heat generated during the operation of the motor controller. This heat is then dissipated into the environment through components such as radiators, thereby maintaining the stability of the internal temperature of the motor controller and preventing performance degradation or damage caused by overheating. One of the main functions of the water channel cover plate 72 is to protect the cooling water channel from direct impact or damage by external objects, thereby reducing the risk of coolant leakage. The water channel cover plate 72 can also provide certain structural support for the cooling water channel, preventing the pipes from shifting or deforming due to vibration or external forces, and ensuring the stability and reliability of the cooling system.

[0042] In this application, a waterproof and breathable valve 8 is provided on the motor controller housing 2. The primary function of the waterproof and breathable valve 8 is to ensure the waterproofness of the motor controller housing 2. During the operation of the motor, especially in outdoor or humid environments, the waterproof and breathable valve 8 can effectively prevent liquids such as moisture and rainwater from entering the interior through the housing, thereby protecting the motor controller components 1 from moisture and corrosion.

[0043] In this application, the layout of the motor controller components 1 is compact, and each component can be disassembled independently, effectively improving the modularity of a single motor controller and reducing the configuration volume of the motor controller housing 2.

[0044] In the description of this application, it should be noted that the orientation or positional relationship indicated by terms such as "upper" and "lower" is based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing this application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation to this application. Unless otherwise clearly specified and defined, the terms "installed", "connected", and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0045] It should be noted that in this application, relational terms such as "first" and "second" are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the term "comprising", "including" or any other variant thereof is intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements not only includes those elements, but also includes other elements not expressly listed, or also includes elements inherent to such process, method, article or device. Without further limitation, an element defined by the statement "comprising an..." does not exclude the presence of additional identical elements in the process, method, article or device comprising the element.

[0046] The above are only specific embodiments of the present application, enabling those skilled in the art to understand or implement the present application. Various modifications to these embodiments will be obvious to those skilled in the art, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application will not be limited to these embodiments shown herein, but rather will conform to the widest scope consistent with the principles and novel features claimed herein.

Claims

1. A motor controller, characterized in that: include: A motor control device (1), comprising a capacitor (10), a high voltage input connector (11) and a shielding magnetic ring (12); A motor controller housing (2) having an accommodating cavity (20) formed therein, wherein the capacitor (10) is installed in the accommodating cavity (20); The top of the installation box (3) is in communication with the accommodating cavity (20); the bottom of the installation box (3) is provided with an installation opening (30); the high-voltage input connector (11) is connected to the bottom of the installation box (3); the shielding magnetic ring (12) is installed in the installation box (3); and the shielding magnetic ring (12) and the high-voltage input connector (11) are connected via the installation opening (30).

2. A motor controller as claimed in claim 1, characterized in that: An operating window (31) is provided on one side of the installation box (3), and a window cover plate (310) is connected to the operating window (31) on the installation box (3).

3. A motor controller as claimed in claim 1, characterized in that: The motor control device (1) further comprises: An IGBT module (13) is installed in the accommodating cavity (20), and the capacitor (10) is connected to a lead-out copper busbar of the IGBT module (13); A three-phase copper busbar terminal block (14) is installed in the accommodating cavity (20) and is electrically connected to the IGBT module (13); A three-phase lead-out copper busbar (15), which is installed in the accommodating cavity (20) and connected to the three-phase copper busbar terminal block (14); A high-voltage output connector (16) is installed on one side of the motor controller housing (2), and the high-voltage output connector (16) passes through the motor controller housing (2) and is connected to the three-phase lead-out copper busbar (15).

4. A motor controller as claimed in claim 3, characterized in that: A PCB board (4) is provided in the accommodating cavity (20) and is located on the IGBT module (13), the capacitor (10) and the three-phase copper busbar (130) connection wire seat. A current sensor (40) and a resolver connector (41) are provided on the PCB board (4). A resolver signal plug-in (5) is also provided on the motor controller housing (2). The resolver signal plug-in (5) is electrically connected to the resolver connector (41).

5. A motor controller as claimed in claim 3, characterized in that: A low-voltage connector (6) is also provided in the accommodating cavity (20).

6. A motor controller as claimed in claim 1, characterized in that: A cooling water channel is also provided on the motor controller housing (2), and a water channel cover plate (72) is also provided on the cooling water channel in the accommodating cavity (20).

7. A motor controller as claimed in claim 1, characterized in that: The motor controller housing (2) is provided with a waterproof and breathable valve (8).

8. A motor controller as claimed in claim 3, characterized in that: The three-phase copper busbar terminal block (14) is provided with a metal shielding cover (140).

9. A motor controller as claimed in claim 1, characterized in that: A capacitor mounting cylindrical surface (9) is provided in the accommodating cavity (20).

10. A motor controller as claimed in claim 1, characterized in that: The operating window (31) is provided with a window sealing ring (311).

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