Motor controller, electric drive system and vehicle

Abstract

The application discloses a motor controller, a power drive system and a vehicle, and relates to the technical field of electronics. The motor controller comprises a power device module, a capacitor module and an electrical connection assembly. The electrical connection assembly is a flexible structural member. The electrical connection assembly comprises a first conductive member and a second conductive member. The first conductive member and the second conductive member are coupled to each other. The first conductive member is electrically connected to the power device module and the capacitor module respectively. The second conductive member is electrically connected to the power device module and the capacitor module respectively. The embodiment of the application can solve the problem of a large equivalent series inductance.

Description

Technical Field

[0001] This application relates to the field of electronic technology, and in particular to motor controllers, electric drive systems and vehicles. Background Technology

[0002] The motor control unit (MCU) is a key component in the electric drive system of an electric vehicle, primarily used to control the operation of the motor.

[0003] In related technologies, motor controllers mainly include power device modules and capacitor modules. The capacitor module consists of a copper busbar and a thin-film capacitor. One end of the copper busbar is connected to the thin-film capacitor, and the other end is connected to the power device module via screws. During operation, the current is filtered by the thin-film capacitor and then output to the power device module through the copper busbar.

[0004] However, in the aforementioned technologies, because the power device module and the film capacitor are directly connected via copper busbars, the equivalent series inductance (ESL) at the interconnection terminals of the power device module and the film capacitor is relatively large. This further leads to the power device module being subjected to greater voltage stress, and may even cause damage to the power device module. In addition, a large ESL also increases switching losses, thereby reducing the efficiency of the motor controller and hindering the development of motor controllers towards high density, high efficiency, and miniaturization. Summary of the Invention

[0005] This application provides a motor controller, an electric drive system, and a vehicle to solve the problem of large equivalent series inductance. The technical solution is as follows:

[0006] Firstly, a motor controller is provided, comprising a power device module, a capacitor module, and an electrical connection assembly. The power device module and the capacitor module are two functional devices, each configured within the motor controller and performing its own function. The electrical connection assembly is disposed between the power device module and the capacitor module, serving to electrically connect them. The electrical connection assembly is a flexible structural component, meaning it can deform under external force. During the assembly of the electrical connection assembly between the power device module and the capacitor module, its shape can be flexibly changed according to requirements, facilitating installation between the electrical connection assembly and the power device module and the capacitor module. The electrical connection assembly mainly includes a first conductive element and a second conductive element, which are coupled to each other; that is, changes in current or voltage between the first and second conductive elements will affect each other. The first conductive element is electrically connected to both the power device module and the capacitor module, with the current flowing from the power device module to the capacitor module. Similarly, the second conductive element is also electrically connected to both the power device module and the capacitor module, with the current flowing from the capacitor module to the power device module. In other words, the current directions in the first and second conductive elements are opposite. This mutual inductance between the first and second conductive elements cancels out their self-inductance, effectively reducing the equivalent series inductance at the interconnection between the power device module and the capacitor module.

[0007] The motor controller provided in this application embodiment has at least the following effects:

[0008] Because the electrical connection assembly includes a first conductive element and a second conductive element, which are coupled to each other, and the current direction in the first conductive element is opposite to that in the second conductive element, the mutual inductance generated between the first and second conductive elements can cancel out the self-inductance generated by the first and second conductive elements themselves. This effectively reduces the equivalent series inductance of the interconnection between the power device module and the capacitor module, thus facilitating the development of motor controllers towards high density, high efficiency, and miniaturization. Furthermore, the electrical connection assembly is a flexible structural component, allowing for flexible shape changes according to requirements. This facilitates the installation of the electrical connection assembly with the power device module and the capacitor module, preventing damage to the power device module and capacitor module due to forced installation.

[0009] In one implementation of this application, the first conductive element includes a first main conductive portion and a first electrical connection portion. The first main conductive portion is the main body of the first conductive element, serving both to conduct current and to support the first electrical connection portion. The first electrical connection portion connects the power device assembly and the capacitor module, with one end connected to the power device module and the other end connected to the capacitor module. The second conductive element includes a second main conductive portion and a second electrical connection portion. The second main conductive portion is the main body of the second conductive element, serving both to conduct current and to support the second electrical connection portion. The second electrical connection portion connects the power device assembly and the capacitor module, with one end connected to the power device module and the other end connected to the capacitor module.

[0010] In other words, the first conductive component achieves electrical connection with the power device module and the capacitor module through its first electrical connection portion, and the second conductive component achieves electrical connection with the power device module and the capacitor module through its second electrical connection portion.

[0011] In one implementation of this application, the two ends of the first electrical connection portion are located on opposite sides of the first main conductive portion, and the two ends of the second electrical connection portion are located on opposite sides of the second main conductive portion.

[0012] In this way, the two ends of the first electrical connection can be easily connected to the power device module and the capacitor module located on opposite sides of the first main conductive part. Correspondingly, the two ends of the second electrical connection can also be easily connected to the power device module and the capacitor module located on opposite sides of the second main conductive part. This design of the positions of the first and second electrical connections allows for a more rational arrangement of the motor controller, which is beneficial for miniaturization.

[0013] In one implementation of this application, the first conductive element includes a plurality of first electrical connection portions, which are arranged at intervals along the length direction of the first main conductive portion. Correspondingly, the second conductive element includes a plurality of second electrical connection portions, which are arranged at intervals along the length direction of the second main conductive portion.

[0014] With this design, each of the first electrical connection parts and the second electrical connection parts can be connected to the power device module and the capacitor module, which is more conducive to the flexible arrangement of the power device module and the capacitor module, making the arrangement of the motor controller more reasonable and conducive to miniaturization design.

[0015] In one implementation of this application, the orthographic projection of the first electrical connection portion onto the plane where the second electrical connection portion is located is spaced apart from the second electrical connection portion. That is, the first electrical connection portion and the second electrical connection portion are offset from each other, and there is no overlap between them.

[0016] In this way, interference and collision between the first electrical connection part and the second electrical connection part can be avoided, effectively improving the reliability of the electrical connection assembly.

[0017] In one implementation of this application, the electrical connection component is a flexible structural element. In this first implementation, both the first and second conductive elements are flexible conductive wires. Utilizing the characteristics of these flexible conductive wires, the first and second conductive elements can deform under external force while maintaining good conductivity. Furthermore, the flexible conductive wires are wrapped with an insulating layer, and their ends have electrical connection terminals. This ensures that the first and second conductive elements do not experience short circuits and can be electrically connected to the power device module and the capacitor module respectively through their respective electrical connection terminals.

[0018] This design allows the electrical connection component to deform under external force, maintain good conductivity, and avoid problems such as short circuits.

[0019] In one implementation of this application, the electrical connection component is a flexible structural element. A second implementation is as follows: the electrical connection component is a flexible printed circuit board (PCB). Utilizing the characteristics of the flexible PCB, the electrical connection component can deform under external force while maintaining good conductivity. The first conductive element is the first wiring layer of the flexible PCB, and the second conductive element is the second wiring layer of the flexible PCB. This ensures that there is no short circuit between the first and second conductive elements, while allowing for electrical connections with the power device module and the capacitor module, respectively.

[0020] This design allows the electrical connection component to deform under external force, maintain good conductivity, and avoid problems such as short circuits.

[0021] In one implementation of this application, the power device module includes a power chip and a printed circuit board, with the power chip embedded within the printed circuit board. In other words, the power device module is a chip-embedded package.

[0022] This design enables the power device module to be a chip-embedded package, which can effectively improve the integration of the power device module, make the circuit design within the power device module more reasonable, and help reduce the parasitic inductance of the power device module itself.

[0023] In one implementation of this application, one side of the printed circuit board has a pad, which serves as the connection basis for the first conductive element and the second conductive element, and the pad is soldered to the first conductive element and the second conductive element respectively.

[0024] In this way, on the one hand, reliable electrical connection between the first conductive element and the second conductive element and the power device module is ensured, and on the other hand, the connection efficiency between the first conductive element and the second conductive element and the power device module is improved.

[0025] In one implementation of this application, the motor controller further includes a heat sink, and an insulating thermally conductive layer is provided between the heat sink and the power device module, and between the heat sink and the capacitor module.

[0026] In this way, the heat sink effectively dissipates heat from the power device module and the capacitor module, ensuring they operate at suitable temperatures and guaranteeing the reliability of the motor controller. Furthermore, the heat sink and the power device module, as well as the heat sink and the capacitor module, achieve indirect contact through the insulating thermally conductive layer. This ensures insulation performance between the heat sink and the power device module, and between the heat sink and the capacitor module, improving the reliability of the motor controller. It also facilitates heat dissipation from the power device module and the capacitor module through the heat sink.

[0027] In a second aspect, an electric drive system is provided, the electric drive system including the motor controller described in the first aspect.

[0028] The electric drive system provided in this application embodiment has at least the following effects:

[0029] Since the electric drive system includes the motor controller described in the first aspect, and the electrical connection component of the motor controller includes a first conductive element and a second conductive element, the first conductive element and the second conductive element are coupled to each other, and the current direction in the first conductive element is opposite to the current direction in the second conductive element, the mutual inductance generated between the first conductive element and the second conductive element can be canceled out with the self-inductance generated by the first conductive element and the second conductive element themselves. This effectively reduces the equivalent series inductance of the interconnection terminal of the power device module and the capacitor module, which is conducive to the development of the motor controller towards high density, high efficiency and miniaturization, and thus enables the electric drive system to have the characteristics of high density, high efficiency and miniaturization.

[0030] Thirdly, a vehicle is provided, the vehicle including the electric drive system described in the second aspect.

[0031] The vehicle provided in this application embodiment has at least the following effects:

[0032] Since the vehicle includes the electric drive system described in the second aspect, and the electric drive system is characterized by high density, high efficiency, and miniaturization, this is beneficial in two ways: firstly, it increases the interior space of the vehicle, and secondly, it improves the vehicle's safety performance and range. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of the structure of the motor controller provided in the embodiments of this application;

[0034] Figure 2This is a schematic diagram illustrating the connection between the power device module and the capacitor module provided in an embodiment of this application.

[0035] Figure 3 A schematic diagram showing the current direction of the first and second conductive elements provided in the embodiments of this application;

[0036] Figure 4 This is a schematic diagram illustrating the connection between the power device module and the capacitor module provided in an embodiment of this application.

[0037] Figure 5 This is a schematic diagram of the structure of the motor controller provided in the embodiments of this application;

[0038] Figure 6 This is a schematic diagram of the structure of the motor controller provided in an embodiment of this application.

[0039] Marker explanation:

[0040] 10. Power device modules;

[0041] 10a. Submodule;

[0042] 110. Power chip; 120. Printed circuit board; 130. Solder pad;

[0043] 20. Capacitor module;

[0044] 30. Electrical connection components;

[0045] 310. First conductive element; 311. First main conductive part; 312. First electrical connection part;

[0046] 320. Second conductive element; 321. Second main conductive part; 322. Second electrical connection part;

[0047] 330. Insulating film;

[0048] 40. Radiator;

[0049] 410. Insulating and thermally conductive layer.

[0050] The accompanying drawings have illustrated specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concept of this application to those skilled in the art through reference to specific embodiments. Detailed Implementation

[0051] The terminology used in the implementation section of this application is for the purpose of explaining the embodiments of this application only, and is not intended to limit this application.

[0052] An electric vehicle is a vehicle that uses electricity as its power source.

[0053] This vehicle includes an electric drive system, which primarily enables the vehicle to operate electrically. The motor control unit (MCU) is a key component of the electric drive system, mainly used to control the operation of the electric motor. As electric vehicles develop towards safety, intelligence, energy efficiency, long range, and larger vehicle space, motor controllers are also evolving towards higher efficiency, miniaturization, and lighter weight. The main technological directions for improving the performance parameters of motor controllers are as follows: First, the evolution from insulated-gate bipolar transistors (IGBTs) to silicon carbide power MOSFETs (SMTs) can reduce the losses of power device modules in the motor controller, especially switching losses. Second, the bus voltage is increased from 400V to 800V, thereby reducing the operating current while maintaining power output. Third, the integration and miniaturization of power device modules enable them to have low thermal resistance and low parasitic inductance.

[0054] In related technologies, motor controllers mainly include power device modules and capacitor modules. The capacitor module consists of a copper busbar and a thin-film capacitor. One end of the copper busbar is connected to the thin-film capacitor, and the other end is connected to the power device module via screws. During operation, the current is filtered by the thin-film capacitor and then output to the power device module through the copper busbar.

[0055] However, in the aforementioned technologies, because the power device module and the film capacitor are directly connected via copper busbars, the equivalent series inductance (ESL) at the interconnection terminals of the power device module and the film capacitor is relatively large. This further leads to the power device module being subjected to greater voltage stress, and may even cause damage to the power device module. In addition, a large ESL also increases switching losses, thereby reducing the efficiency of the motor controller and hindering the development of motor controllers towards high density, high efficiency, and miniaturization.

[0056] To address the aforementioned technical problems, this application provides a motor controller. Figure 1 This is a schematic diagram of the motor controller, combined with... Figure 1 In this embodiment, the motor controller includes a power device module 10, a capacitor module 20, and an electrical connection component 30.

[0057] In the above implementation, the power device module 10 and the capacitor module 20 are two functional devices, each configured in the motor controller and capable of performing its own function. The electrical connection component 30 is disposed between the power device module 10 and the capacitor module 20, serving to electrically connect the power device module 10 and the capacitor module 20.

[0058] Figure 2This is a schematic diagram showing the connection between the power device module 10 and the capacitor module 20. Figure 2 The perspective is Figure 1 In the direction A.

[0059] Combination Figure 2 In this embodiment, the electrical connection component 30 includes a first conductive element 310 and a second conductive element 320. The first conductive element 310 and the second conductive element 320 are coupled to each other. The first conductive element 310 is electrically connected to the power device module 10 and the capacitor module 20 respectively. The current direction in the first conductive element 310 is from the power device module 10 to the capacitor module 20. The second conductive element 320 is electrically connected to the power device module 10 and the capacitor module 20 respectively. The current direction in the second conductive element 320 is from the capacitor module 20 to the power device module 10.

[0060] Figure 3 This is a schematic diagram showing the current direction in the first conductive element 310 and the second conductive element 320. Figure 3 The solid arrow in the middle indicates the direction of the current.

[0061] Combination Figure 3 In the above implementation, since the first conductive element 310 and the second conductive element 320 are coupled to each other, the current changes or voltage changes between the first conductive element 310 and the second conductive element 320 will have mutual influence. Furthermore, the current direction in the first conductive element 310 and the current direction in the second conductive element 320 are opposite. In this way, the mutual inductance generated between the first conductive element 310 and the second conductive element 320 can cancel out the self-inductance generated by the first conductive element 310 and the second conductive element 320 themselves, thereby effectively reducing the equivalent series inductance of the interconnection between the power device module 10 and the capacitor module 20.

[0062] The motor controller provided in this application embodiment has at least the following effects:

[0063] Since the electrical connection component 30 includes a first conductive element 310 and a second conductive element 320, the first conductive element 310 and the second conductive element 320 are coupled to each other, and the current direction in the first conductive element 310 is opposite to the current direction in the second conductive element 320, the mutual inductance generated between the first conductive element 310 and the second conductive element 320 can be canceled out with the self-inductance generated by the first conductive element 310 and the second conductive element 320 themselves. This effectively reduces the equivalent series inductance of the interconnection terminal of the power device module 10 and the capacitor module 20, which is conducive to the development of motor controller towards high density, high efficiency and miniaturization.

[0064] As can be seen from the preceding text, the first conductive element 310 and the second conductive element 320 play a key role in reducing the equivalent series inductance of the interconnection termination between the power device module 10 and the capacitor module 20. The first conductive element 310 and the second conductive element 320 of the electrical connection assembly 30 will be further described below.

[0065] See you again Figure 2 In this embodiment, the first conductive element 310 includes a first main conductive part 311 and a first electrical connection part 312. The first electrical connection part 312 is connected to the first main conductive part 311. One end of the first electrical connection part 312 is connected to the power device module 10, and the other end of the first electrical connection part 312 is connected to the capacitor module 20.

[0066] In the above implementation, the first main conductive part 311 is the main body of the first conductive component 310. On the one hand, it can conduct current, and on the other hand, it can carry the first electrical connection part 312. The first electrical connection part 312 can connect the power device assembly and the capacitor module 20.

[0067] For example, the first main conductive part 311 and the first electrical connection part 312 are integral structural components.

[0068] This design can improve the overall structural integrity of the first conductive element 310 to ensure structural strength, and also improve the manufacturing efficiency of the first conductive element 310.

[0069] See also Figure 2 In this embodiment, the second conductive element 320 includes a second main conductive part 321 and a second electrical connection part 322. The second electrical connection part 322 is connected to the second main conductive part 321. One end of the second electrical connection part 322 is connected to the power device module 10, and the other end of the second electrical connection part 322 is connected to the capacitor module 20.

[0070] In the above implementation, the second main conductive part 321 is the main body of the second conductive member 320. On the one hand, it can conduct current, and on the other hand, it can carry the second electrical connection part 322. The second electrical connection part 322 serves to connect the power device assembly and the capacitor module 20.

[0071] For example, the second main conductive part 321 and the second electrical connection part 322 are integral structural components.

[0072] This design can improve the overall structural integrity of the second conductive element 320 to ensure structural strength, and also improve the manufacturing efficiency of the second conductive element 320.

[0073] In this embodiment, both the first main conductive portion 311 and the first electrical connection portion 312 are plate-shaped structures, and are located on a first plane. Both the second main conductive portion 321 and the second electrical connection portion 322 are plate-shaped structures, and are located on a second plane. The first plane and the second plane are spaced apart from each other and parallel to each other.

[0074] In the above implementation, a surface-to-surface coupling is formed between the first conductive element 310 and the second conductive element 320. This effectively increases the coupling area between the first conductive element 310 and the second conductive element 320, thereby improving the coupling strength and increasing the mutual inductance. This, in turn, helps to reduce the equivalent series inductance of the interconnection termination between the power device module 10 and the capacitor module 20.

[0075] It is worth noting that the distance between the first conductive element 310 and the second conductive element 320 can also affect the coupling strength between them. The greater the distance between the first conductive element 310 and the second conductive element 320, the stronger the coupling strength; conversely, the smaller the distance between them, the weaker the coupling strength.

[0076] For example, the distance between the first conductive element 310 and the second conductive element 320 is 0.2 mm to 2 mm.

[0077] In the above implementation, the spacing between the first conductive element 310 and the second conductive element 320 is designed to the above value. On the one hand, this can ensure the coupling strength between the first conductive element 310 and the second conductive element 320, and on the other hand, it can also ensure the miniaturization design of the electrical connection assembly 30.

[0078] In this embodiment, the distance between the first conductive element 310 and the second conductive element 320 is 1 mm.

[0079] Of course, in other embodiments, the spacing between the first conductive element 310 and the second conductive element 320 can also be other values ​​within the above range, and this application does not limit this.

[0080] In other embodiments, the first plane and the second plane may also have an angle, which is an acute angle.

[0081] For example, the angle between the first plane and the second plane is 10° to 30°. Of course, the angle between the first plane and the second plane can be adjusted according to actual needs, and this application does not limit it.

[0082] See also Figure 2In this embodiment, the two ends of the first electrical connection portion 312 are located on opposite sides of the first main conductive portion 311.

[0083] In this way, the two ends of the first electrical connection portion 312 can be easily connected to the power device module 10 and the capacitor module 20 located on opposite sides of the first main conductive portion 311.

[0084] In the above implementation, the portion between the two ends of the first electrical connection portion 312 is connected to the first main conductive portion 311, such that the two ends of the first electrical connection portion 312 are located on opposite sides of the first main conductive portion 311.

[0085] Of course, in other embodiments, if the power device module 10 and the capacitor module 20 are located on the same side of the first main conductive portion 311, then correspondingly, both ends of the first electrical connection portion 312 are located on the same side of the first main conductive portion 311. That is to say, the position of the end of the first electrical connection portion 312 on the first main conductive portion 311 is determined by the arrangement of the power device module 10 and the capacitor module 20.

[0086] In this embodiment, the two ends of the second electrical connection portion 322 are located on opposite sides of the second main conductive portion 321.

[0087] In this way, the two ends of the second electrical connection part 322 can also be easily connected to the power device module 10 and the capacitor module 20 located on opposite sides of the second main conductive part 321.

[0088] In the above implementation, the portion between the two ends of the second electrical connection portion 322 is connected to the second main conductive portion 321, such that the two ends of the second electrical connection portion 322 are located on opposite sides of the second main conductive portion 321.

[0089] Of course, in other embodiments, if the power device module 10 and the capacitor module 20 are located on the same side of the second main conductive portion 321, then correspondingly, both ends of the second electrical connection portion 322 are located on the same side of the second main conductive portion 321. That is to say, the position of the end of the second electrical connection portion 322 on the second main conductive portion 321 is determined by the arrangement of the power device module 10 and the capacitor module 20 to meet the design requirements of miniaturization.

[0090] See also Figure 2In this embodiment, both the first main conductive part 311 and the second main conductive part 321 are elongated structural components. The number of the first electrical connection part 312 and the second electrical connection part 322 can be adjusted according to requirements. If the first conductive part 310 includes multiple first electrical connection parts 312 and the second conductive part 320 includes multiple second electrical connection parts 322, then the multiple first electrical connection parts 312 are arranged sequentially at intervals along the length direction of the first main conductive part 311, and the multiple second electrical connection parts 322 are arranged sequentially at intervals along the length direction of the second main conductive part 321.

[0091] In the above implementation, each of the first electrical connection parts 312 and the second electrical connection parts 322 can be connected to the power device module 10 and the capacitor module 20, which is more conducive to the flexible arrangement of the power device module 10 and the capacitor module 20, making the arrangement of the motor controller more reasonable and conducive to miniaturization design.

[0092] For example, since either the first electrical connection portion 312 or the second electrical connection portion 322 can be connected to the power device module 10 and the capacitor module 20, when connecting the power device module 10 and the capacitor module 20 through the electrical connection assembly 30, the appropriate first electrical connection portion 312 and second electrical connection portion 322 can be selected to be connected according to the position between the power device module 10 and the capacitor module 20, which is beneficial for reasonable arrangement.

[0093] For example, the length directions of the first main conductive part 311 and the second main conductive part 321 are parallel to each other.

[0094] This design facilitates planning the arrangement of the first conductive element 310 and the second conductive element 320.

[0095] In other embodiments, the first main conductive portion 311 and the second main conductive portion 321 can also be structural components of other shapes, such as circular structural components. In this case, the first electrical connection portions 312 are arranged sequentially at intervals along the circumference of the first main conductive portion 311, and the second electrical connection portions 322 are arranged sequentially at intervals along the circumference of the second main conductive portion 321. In this way, the power device module 10 and the capacitor module 20 are arranged accordingly along the circumference of the first main conductive portion 311 and the second main conductive portion 321.

[0096] For example, the orthographic projection of the first main conductive part 311 onto the plane where the second main conductive part 321 is located coincides with the second main conductive part 321.

[0097] This design allows the first conductive element 310 and the second conductive element 320 to be arranged relatively compactly, which is beneficial for achieving miniaturization of the motor controller.

[0098] In this embodiment, the number of first electrical connection portions 312 and second electrical connection portions 322 is the same. One first electrical connection portion 312 and one second electrical connection portion 322 form a group. Each group of first electrical connection portions 312 and second electrical connection portions 322 are arranged sequentially at intervals along the same direction. The current directions of the first electrical connection portions 312 and second electrical connection portions 322 in the same group are opposite.

[0099] This arrangement of the first conductive element 310 and the second conductive element 320 makes it easier to plan the electrical connections between the first conductive element 310 and the second conductive element 320 and the power device module 10 and the capacitor module 20.

[0100] In this embodiment, the power device module 10 includes multiple sub-modules 10a, which are arranged at intervals.

[0101] In the above implementation, each sub-module 10a of the power device module 10 corresponds to a set of first electrical connection portion 312 and second electrical connection portion 322. If the first main conductive portion 311 and the second main conductive portion 321 are both elongated structural components, then each sub-module 10a is arranged sequentially at intervals along the length direction of the first main conductive portion 311 and the second main conductive portion 321.

[0102] It is worth noting that, although Figure 2 and Figure 4 Only three submodules 10a are shown in the document, but the number of submodules 10a can be adjusted according to actual needs, such as two or four, and this application does not limit this.

[0103] See also Figure 2 In this embodiment, the orthographic projection of the first electrical connection portion 312 onto the plane where the second electrical connection portion 322 is located is spaced apart from the second electrical connection portion 322. That is, the first electrical connection portion 312 and the second electrical connection portion are offset from each other, and there is no overlap between them.

[0104] In the above implementation, mutual interference and collision between the first electrical connection part 312 and the second electrical connection part 322 can be avoided, effectively improving the reliability of the electrical connection assembly 30.

[0105] Of course, in other embodiments, the orthographic projection of the first electrical connection portion 312 onto the plane where the second electrical connection portion 322 is located mostly coincides with the second electrical connection portion 322, and a small portion, such as the connection end, is spaced apart from the second electrical connection portion 322.

[0106] This design allows most of the first electrical connection portion 312 and the second electrical connection portion 322 to overlap, resulting in a more compact arrangement between them and facilitating the miniaturization of the motor controller. Furthermore, the spaced connection ends of the first electrical connection portion 312 and the second electrical connection portion 322 facilitate wiring.

[0107] As mentioned above, the connecting component connects between the power device module 10 and the capacitor module 20, thus achieving an electrical connection between them. Due to tolerances, the relative positions of the power device module 10 and the capacitor module 20 cannot be guaranteed to be exactly the same as designed. This means that the electrical connecting component 30 cannot connect the power device module 10 and the capacitor module 20 together according to the designed position. If the power device module 10 and the capacitor module 20 are forcibly connected under these tolerance conditions, the connection points of the power device module 10 may be damaged, or even the power device module 10 may be destroyed, because the size of the power device module 10 is much smaller than that of the capacitor module 20.

[0108] In order to compensate for the relative positional tolerance between the power device module 10 and the capacitor module 20, in this embodiment, the electrical connection component 30 is a flexible structural component. That is, the electrical connection component 30 can undergo a certain deformation under the action of external force, thereby compensating for the relative positional tolerance between the power device module 10 and the capacitor module 20.

[0109] In the above implementation, during the process of assembling the electrical connection component 30 between the power device module 10 and the capacitor module 20, the shape of the electrical connection component 30 can be flexibly changed according to the requirements, thereby facilitating the installation of the electrical connection component 30 between the power device module 10 and the capacitor module 20.

[0110] In this embodiment, two implementation methods are provided for the electrical connection component 30 to be a flexible structural member. It is worth noting, however, that while this embodiment provides two implementation methods, it is not limited to only these two methods.

[0111] The first implementation method will be explained below.

[0112] See also Figure 2 In this embodiment, both the first conductive element 310 and the second conductive element 320 are flexible conductive wires, which are wrapped with an insulating layer and have electrical connection terminals at their ends.

[0113] In the above implementation, the characteristics of the flexible conductive wire are utilized so that the first conductive element 310 and the second conductive element 320 can both deform under external force and maintain good conductivity. Furthermore, the flexible conductive wire is wrapped with an insulating layer, and its ends have electrical connection terminals. This ensures that the first conductive element 310 and the second conductive element 320 will not experience short circuits, and that they can be electrically connected to the power device module 10 and the capacitor module 20 respectively through their respective electrical connection terminals.

[0114] This design allows the electrical connection component 30 to deform under external force, while maintaining good conductivity and preventing short circuits.

[0115] For example, the first conductive element 310 and the second conductive element 320 are both copper strip wires or copper foil wires. The first conductive element 310 and the second conductive element 320 are wrapped with an insulating layer. The ends of the first conductive element 310 and the second conductive element 320 are not wrapped with an insulating layer and are electrically connected to terminals, thereby realizing electrical connection with the power device module 10 and the capacitor module 20.

[0116] For example, the insulating layer outside the first conductive element 310 and the second conductive element 320 can also be an insulating varnish. Applying the insulating varnish to the outer wall of the first conductive element 310 and the second conductive element 320 can also form an insulating layer to achieve the effect of insulation.

[0117] The second implementation method will be explained below.

[0118] Figure 4 This is a schematic diagram showing the connection between the power device module 10 and the capacitor module 20. Figure 4 and Figure 2 The difference lies in the form of the electrical connection component 30, combined with Figure 4 In this embodiment, the electrical connection component 30 is a flexible printed circuit (FPC), the first conductive element 310 is the first wiring layer of the flexible printed circuit, and the second conductive element 320 is the second wiring layer of the flexible printed circuit.

[0119] In the above implementation, the electrical connection component 30 is a flexible printed circuit board. Utilizing the characteristics of a flexible printed circuit board, the electrical connection component 30 can undergo a certain degree of deformation under external force while maintaining good conductivity. In this case, the first conductive element 310 is the first wiring layer of the flexible printed circuit board, and the second conductive element 320 is the second wiring layer of the flexible printed circuit board. This ensures that there is no short circuit between the first conductive element 310 and the second conductive element 320, while enabling them to be electrically connected to the power device module 10 and the capacitor module 20 respectively.

[0120] This design allows the electrical connection component 30 to deform under external force, while maintaining good conductivity and preventing short circuits.

[0121] It is worth noting that, since the flexible printed circuit board includes an insulating film 330, and the first wiring layer and the second wiring layer are disposed on the insulating film 330, the insulation between the first wiring layer and the second wiring layer can be guaranteed.

[0122] In this embodiment, because the flexible printed circuit board has high integration, SMD (surface mount device) capacitors or other driving circuit devices can also be integrated on the flexible printed circuit board.

[0123] This design facilitates the integrated and miniaturized design of the motor controller.

[0124] For example, flexible printed circuit boards can integrate electronic components such as ceramic capacitors and driver chips.

[0125] It is worth noting that when high-voltage ceramic capacitors are integrated on flexible printed circuit boards, in addition to being beneficial for miniaturization design, they can also effectively reduce high-frequency ripple on the bus voltage, thereby reducing the equivalent series inductance.

[0126] As can be seen from the preceding text, both the first and second implementation methods enable the electrical connection component 30 to undergo a certain deformation under the action of external force, while also possessing good conductivity and avoiding problems such as short circuits.

[0127] See you again Figure 1 In this embodiment, the power device module 10 includes a power chip 110 and a printed circuit board 120, with the power chip 110 embedded in the printed circuit board 120.

[0128] In the above implementation, the power chip 110 is embedded in the printed circuit board 120, so that the power device module 10 is a chip-embedded package.

[0129] This design, benefiting from the characteristics of embedded chip packaging, can effectively improve the integration of the power device module 10, making the circuit design within the power device module 10 more reasonable, reducing the length of each circuit in the power device module 10, and helping to reduce the parasitic inductance of the power device module 10 itself.

[0130] Power chip 110 is a high-power chip. For example, power chip 110 is an insulated gate bipolar transistor, a metal-oxide-semiconductor field-effect transistor, etc.

[0131] In this embodiment, one side of the printed circuit board 120 has a pad 130, which serves as the connection base for the first conductive element 310 and the second conductive element 320. The pad 130 is soldered to the first conductive element 310 and the second conductive element 320 respectively.

[0132] In this way, the first conductive element 310 and the second conductive element 320 are both connected to the power device module 10 by welding. On the one hand, this ensures a reliable electrical connection between the first conductive element 310 and the second conductive element 320 and the power device module 10. On the other hand, it also improves the connection efficiency between the first conductive element 310 and the second conductive element 320 and the power device module 10.

[0133] For example, the welding between the first electrical connection 312 and the pad 130, and the welding between the second electrical connection 322 and the pad 130, are reflow soldering.

[0134] The power device module 10, which is in an embedded package, is small in size and has no external soldering pins. It is mainly connected by pads 130 (surface mount pads), so it is more sensitive to mechanical stress. If the power device module 10 is directly rigidly connected under the condition of tolerance, it will cause the pads 130 to break, or even damage the power device module 10.

[0135] In this embodiment, the electrical connection component 30 is set as a flexible structural component, which solves the above problems and effectively improves the assembly reliability and ease of assembly of the motor controller.

[0136] The other beneficial effects of setting the electrical connection assembly 30 as a flexible structural component have been described above and will not be repeated here.

[0137] See also Figure 1 In this embodiment, the motor controller also includes a heat sink 40, and the power device module 10 and the capacitor module 20 are in contact with the heat sink 40.

[0138] In this way, the heat sink 40 can effectively dissipate heat from the power device module 10 and the capacitor module 20, ensuring that the power device module 10 and the capacitor module 20 can operate at a suitable temperature, thus guaranteeing the reliability of the motor controller.

[0139] In some examples, the radiator 40 is an air-cooled radiator, and in other examples, the radiator 40 is a liquid-cooled radiator. This application does not limit this.

[0140] For example, the power device module 10 and the capacitor module 20 are located on the same side of the heat sink 40, and the power device module 10 and the capacitor module 20 are arranged side by side with spacing between them.

[0141] This arrangement of the power device module 10 and capacitor module 20 on the heat sink 40 makes it easier to assemble them on the heat sink 40, and also makes it easier to install the connecting components between the power device module 10 and capacitor module 20.

[0142] In this embodiment, when the power device module 10 and the capacitor module 20 are located on the same side of the heat sink 40, the power device module 10 is used to connect to the outer wall of the electrical connection assembly 30, and the capacitor module 20 is used to connect to the outer wall of the electrical connection assembly 30.

[0143] This design makes it easy to connect the electrical connection component 30 to the power device module 10 and the capacitor module 20 respectively.

[0144] Of course, in other embodiments, the outer wall of the power device module 10 used to connect to the electrical connection component 30 and the outer wall of the capacitor module 20 used to connect to the electrical connection component 30 may not be flush, but in the vertical direction (perpendicular to the horizontal plane), the outer wall of the power device module 10 should be slightly higher than the outer wall of the capacitor module 20.

[0145] This design makes it easier for the electrical connection component 30 to connect to the smaller power device module 10.

[0146] For example, an insulating thermally conductive layer 410 is provided between the heat sink 40 and the power device module 10, and between the heat sink 40 and the capacitor module 20.

[0147] In other words, the heat sink 40 and the power device module 10 are indirectly contacted through the insulating thermally conductive layer 410, and the heat sink 40 and the capacitor module 20 are indirectly contacted through the insulating thermally conductive layer 410.

[0148] This design ensures the insulation performance between the heat sink 40 and the power device module 10, as well as between the heat sink 40 and the capacitor module 20, thus improving the reliability of the motor controller. On the other hand, it also facilitates the heat dissipation of the power device module 10 and the capacitor module 20 by the heat sink 40.

[0149] In some examples, the insulating thermally conductive layer 410 is a thermally conductive material such as silicone grease or gel.

[0150] In other examples, the insulating thermally conductive layer 410 is a soldering material such as solder or sintered silver to conduct heat, and a thermally conductive interface material such as hot melt grease or thermally conductive adhesive to provide insulation.

[0151] In other words, the insulating and thermally conductive layer can be either a single insulating and thermally conductive material or a combination of thermally conductive and insulating materials. This application does not impose any restrictions on this.

[0152] Figure 5 This is a schematic diagram of the motor controller. Figure 5 and Figure 1 The main difference lies in the different positions of the power device module 10 and the capacitor module 20 relative to the heat sink 40. Figure 5 In this embodiment, the power device module 10 and the capacitor module 20 are located on opposite sides of the heat sink 40.

[0153] The arrangement of the power device module 10 and capacitor module 20 on the heat sink 40 makes the structure of the motor controller more compact, which is beneficial to the miniaturization design of the motor controller.

[0154] Figure 6 This is a schematic diagram of the motor controller. Figure 6 and Figure 5 The main difference lies in the arrangement of the radiator 40, combined with Figure 6 In this embodiment, the power device module 10 has heat sinks 40 on both sides, and both sides of the power device module 10 are in contact with the heat sinks 40.

[0155] In the above implementation, by providing heat sinks 40 on both sides of the power device module 10, the heat dissipation effect of the power device module 10 is effectively improved.

[0156] This application provides an electric drive system, which includes... Figures 1 to 6 The motor controller shown.

[0157] The electric drive system provided in this application embodiment has at least the following effects:

[0158] Because electric drive systems include Figures 1 to 6 The motor controller shown includes an electrical connection component 30 comprising a first conductive element 310 and a second conductive element 320. The first conductive element 310 and the second conductive element 320 are coupled to each other, and the current direction in the first conductive element 310 is opposite to that in the second conductive element 320. This allows the mutual inductance generated between the first conductive element 310 and the second conductive element 320 to cancel out the self-inductance generated by the first conductive element 310 and the second conductive element 320 themselves. This effectively reduces the equivalent series inductance of the interconnection between the power device module 10 and the capacitor module 20, which is beneficial for the motor controller to develop towards high density, high efficiency, and miniaturization. This also enables the electric drive system to have the characteristics of high density, high efficiency, and miniaturization.

[0159] In this embodiment, the electric drive system includes a motor, which is electrically connected to the power device module 10, and the capacitor module 20 is electrically connected to the battery.

[0160] The motor controller can convert the DC power supplied by the battery into AC power, thereby driving the motor to work and realizing the conversion of electrical energy into kinetic energy.

[0161] For example, the motor controller is located near the motor to facilitate electrical connection between the motor and the power device module 10.

[0162] This application provides a vehicle that includes the electric drive system described above.

[0163] The vehicle provided in this application embodiment has at least the following effects:

[0164] Since the vehicle includes the electric drive system mentioned earlier, and the electric drive system has the characteristics of high density, high efficiency and small size, this is beneficial to both increasing the vehicle's interior space and improving the vehicle's safety performance and range.

[0165] Unless otherwise defined, the technical or scientific terms used herein shall have the ordinary meaning understood by one of ordinary skill in the art to which this disclosure pertains. The terms “first,” “second,” “third,” and similar terms used in this patent application specification and claims do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Similarly, the terms “an” or “a” and similar terms do not indicate a quantity limitation, but rather indicate the presence of at least one. The terms “comprising” or “including” and similar terms mean that the element or object preceding “comprising” or “including” encompasses the element or object listed following “comprising” or “including” and its equivalents, and do not exclude other elements or objects. The terms “connected” or “linked” and similar terms are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. The terms “upper,” “lower,” “left,” “right,” etc., are used only to indicate relative positional relationships, and these relative positional relationships may change accordingly when the absolute position of the described object changes.

[0166] The above specific embodiments further illustrate the purpose, technical solution and beneficial effects of this application. It should be understood that the above are only specific embodiments of this application and are not intended to limit the scope of protection of this application. Any modifications, equivalent substitutions, improvements, etc., made on the basis of the technical solution of this application should be included within the scope of protection of this application.

Claims

1. A motor controller, characterized in that, It includes a power device module (10), a capacitor module (20), and an electrical connection assembly (30); The electrical connection component (30) is a flexible structural component. The electrical connection component (30) includes a first conductive element (310) and a second conductive element (320). The first conductive element (310) and the second conductive element (320) are coupled to each other. The first conductive element (310) is electrically connected to the power device module (10) and the capacitor module (20) respectively. The current direction in the first conductive element (310) is from the power device module (10) to the capacitor module (20). The second conductive element (320) is electrically connected to the power device module (10) and the capacitor module (20) respectively. The current direction in the second conductive element (320) is from the capacitor module (20) to the power device module (10).

2. The motor controller according to claim 1, characterized in that, The first conductive element (310) includes a first main conductive part (311) and a first electrical connection part (312); The first electrical connection part (312) is connected to the first main conductive part (311), one end of the first electrical connection part (312) is connected to the power device module (10), and the other end of the first electrical connection part (312) is connected to the capacitor module (20). The second conductive element (320) includes a second main conductive part (321) and a second electrical connection part (322); The second electrical connection part (322) is connected to the second main conductive part (321), one end of the second electrical connection part (322) is connected to the power device module (10), and the other end of the second electrical connection part (322) is connected to the capacitor module (20).

3. The motor controller according to claim 2, characterized in that, The two ends of the first electrical connection portion (312) are located on opposite sides of the first main conductive portion (311); The two ends of the second electrical connection portion (322) are located on opposite sides of the second main conductive portion (321).

4. The motor controller according to claim 2, characterized in that, The first conductive element (310) includes a plurality of first electrical connection portions (312), which are arranged at intervals along the length of the first main conductive portion (311). The second conductive element (320) includes a plurality of second electrical connection portions (322), which are arranged sequentially at intervals along the length direction of the second main conductive portion (321).

5. The motor controller according to claim 2, characterized in that, The orthographic projection of the first electrical connection portion (312) onto the plane where the second electrical connection portion (322) is located is spaced apart from the second electrical connection portion (322).

6. The motor controller according to any one of claims 1 to 5, characterized in that, Both the first conductive element (310) and the second conductive element (320) are flexible conductive wires, the flexible conductive wires are wrapped with an insulating layer, and the ends of the flexible conductive wires have electrical connection terminals.

7. The motor controller according to any one of claims 1 to 5, characterized in that, The electrical connection component (30) is a flexible printed circuit board, the first conductive element (310) is the first wiring layer of the flexible printed circuit board, and the second conductive element (320) is the second wiring layer of the flexible printed circuit board.

8. The motor controller according to any one of claims 1 to 5, characterized in that, The power device module (10) includes a power chip (110) and a printed circuit board (120); The power chip (110) is embedded in the printed circuit board (120).

9. The motor controller according to claim 8, characterized in that, One side of the printed circuit board (120) has pads (130); The pads (130) are soldered to the first conductive element (310) and the second conductive element (320), respectively.

10. The motor controller according to any one of claims 1 to 5, characterized in that, The motor controller also includes a radiator (40); An insulating and thermally conductive layer (410) is provided between the heat sink (40) and the power device module (10), and between the heat sink (40) and the capacitor module (20).

11. An electric drive system, characterized in that, Includes the motor controller as described in any one of claims 1 to 10.

12. A vehicle, characterized in that, Includes the electric drive system as described in claim 11.

Images