A two-in-one controller based on a six-phase motor controller assembly

Abstract

A two-in-one controller based on six-phase motor controller assembly, including main shell, cooling water channel and two groups of six-phase motor controller assembly, the main shell is divided into upper cavity and lower cavity, and one group of six-phase motor controller assembly is respectively arranged in the upper cavity and the lower cavity; the cooling water channel includes water inlet, upper water channel, lower water channel and water outlet, the upper water channel and the lower water channel are respectively arranged on the upper and lower sides of the partition plate, each group of six-phase motor controller assembly includes two power modules, two DC lines and six AC lines, and the power modules of the two groups of six-phase motor controller assembly are correspondingly arranged on the outer surfaces of the upper water channel and the lower water channel; the rear end surface of the main shell is provided with two power input interfaces and twelve-phase output interfaces, and the power input interfaces and the output interfaces are staggered. The utility model discloses can satisfy the cooling demand of each power module simultaneously, and adjusts the installation mode of DC line and AC line to be unified direction, so as to be convenient for the installation of wire harness.

Description

Technical Field

[0001] This utility model relates to the technical field, and more specifically to a two-in-one controller based on a six-phase motor controller assembly. Background Technology

[0002] With the development of distributed drive systems, there are multiple main drive motors or hub motors, which places higher demands on the output capability and number of output terminals of the controller.

[0003] Currently, most existing motor controllers are three-phase or six-phase output. Six-phase motor controllers primarily employ a traditional stacked structure of two three-phase motor controllers. However, for twelve-phase motor controllers, this simple stacked structure not only increases the space required for controller placement but also makes it impossible to simultaneously cool multiple power modules. Furthermore, the multiple DC and AC wiring connections become quite messy and inconvenient for installation. Therefore, we provide a two-in-one controller based on a six-phase motor controller assembly. Utility Model Content

[0004] This utility model provides a two-in-one controller based on a six-phase motor controller assembly. Its main purpose is to overcome the shortcomings of the existing simple superimposed structure, which is difficult to meet the layout requirements of a twelve-phase motor controller.

[0005] The present invention adopts the following technical solution:

[0006] A two-in-one controller based on a six-phase motor controller assembly includes a main housing, cooling water channels, and two sets of six-phase motor controller assemblies. A partition plate in the middle of the main housing divides it into an upper cavity and a lower cavity. One set of six-phase motor controller assemblies is housed in each of the upper and lower cavities. The cooling water channels include an inlet, an upper channel, a lower channel, and an outlet. The inlet is connected to both the upper and lower channels, and the ends of both channels are connected to the outlet. The upper and lower channels are located on the upper and lower sides of the partition plate, respectively. Each six-phase motor controller assembly includes two power modules, two DC power connectors, and two DC power connectors. The system includes a filter assembly, a capacitor, and six AC wires. The power modules of the two sets of six-phase motor controller assemblies are located on the outer surfaces of the upper and lower water channels, respectively. Each DC wire is connected to the input terminal of the capacitor through a DC filter assembly. The output terminal of the capacitor is connected to the input terminals of the two power modules. The output terminal of each power module is connected to three AC wires through three copper busbars. Two power input interfaces are provided on both sides of the rear end face of the main housing. A twelve-phase output interface is provided between the power input interfaces. The power input interfaces and output interfaces are staggered. Each DC wire enters the main housing from the power input interface, and each AC wire exits from the output interface.

[0007] In a preferred embodiment, the power module of one of the aforementioned six-phase motor controller assemblies is provided with a shielding plate, and a control board is mounted on the shielding plate. The control board communicates with the vehicle controller (VCU) and is electrically connected to the power module.

[0008] In a preferred embodiment, a DC mounting base and an AC mounting base are provided on the side of the rear end face of the main housing. The DC filter assembly is connected to the DC wiring through the DC mounting base, and the copper busbar is connected to the AC wiring through the AC mounting base. Each copper busbar is also provided with a corresponding current sensor.

[0009] In a preferred embodiment, the two sets of six-phase motor controller assemblies are arranged in a symmetrical manner in the upper and lower cavities of the main housing, and the power modules of the two sets of six-phase motor controller assemblies are staggered.

[0010] In a preferred embodiment, the power module is an HPD-packaged SiC power module.

[0011] In a preferred embodiment, the capacitor is a film capacitor with a length, height, and width of 337mm, 50mm, and 82mm, respectively.

[0012] As can be seen from the above description of the structure of this utility model, compared with the prior art, this utility model has the following advantages:

[0013] 1. This utility model divides the main housing into an upper cavity and a lower cavity. Each cavity houses a six-phase motor control assembly, and the cooling water channels are designed for both diversion and equalization. The power modules of each six-phase motor control assembly are located on the outer surfaces of the upper and lower water channels, simultaneously meeting the cooling requirements of each power module and ensuring its normal operation. Furthermore, the rear end face of the main housing has power input and twelve-phase output interfaces on both sides, arranged in a staggered manner. This allows for the adjustment of DC and AC wiring installations to a unified direction, facilitating wiring harness installation.

[0014] 2. The power module adopts HPD-packaged SiC power modules, which can meet the current input requirements of a six-phase motor; while the design of AC and DC mounting brackets helps to meet the requirements of the production process. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of this utility model.

[0016] Figure 2 This is a top view of the present invention.

[0017] Figure 3 for Figure 2 A cross-sectional view along the AA direction.

[0018] Figure 4 This is a longitudinal sectional view of the present invention along the central axis of the AC wiring. Detailed Implementation

[0019] The specific embodiments of this utility model are described below with reference to the accompanying drawings. Many details are described below to provide a comprehensive understanding of this utility model; however, those skilled in the art can implement this utility model without these details. Well-known components, methods, and processes will not be described in detail below.

[0020] This embodiment provides a two-in-one controller based on a six-phase motor controller assembly, referencing... Figures 1 to 4 The system includes a main housing 10, cooling water channels, and two sets of six-phase motor controller assemblies. The top and bottom surfaces of the main housing 10 are respectively provided with an upper cover plate 101 and a lower cover plate 102. A partition plate 103 is provided in the middle of the main housing 10 to divide the main housing into an upper cavity 11 and a lower cavity 12. A set of six-phase motor controller assemblies 30 is respectively provided in the upper cavity 11 and the lower cavity 12.

[0021] Reference Figure 3 and Figure 4 The cooling water channel includes an inlet 21, an upper water channel 22, a lower water channel 23, and an outlet 24. The upper water channel 22 and the lower water channel 23 are respectively located on the upper and lower sides of the partition plate 103 and are staggered. The inlet 21 and the outlet 24 are respectively located on the left and right side walls of the main shell 10. After the water is diverted, the inlet 21 is connected to the upper water channel 22 and the lower water channel 23 respectively. The ends of the upper water channel 22 and the lower water channel 23 are respectively connected to the outlet 24.

[0022] Reference Figures 1 to 4 Each of the aforementioned six-phase motor controller assemblies includes two power modules 31, two DC wires 32, two DC filter components 33, one capacitor 34, six AC wires 35, six copper busbars 36, and six current sensors 37. The outer surface of the upper waterway 22 is equipped with two power modules 31 of one set of six-phase motor controller assemblies, while the outer surface of the lower waterway 23 is equipped with two power modules 31 of another set of six-phase motor controller assemblies. The two power modules 31 on the outer surface of the upper waterway 22 and the two power modules 31 on the outer surface of the lower waterway 23 are staggered. Each DC filter component 33 is connected to one DC wire 32 via a DC mounting bracket 331, and the end of the DC filter component 33 is connected to the input terminal of the capacitor 34. Each copper busbar 36 is connected to one AC wire 35 via an AC mounting bracket 361, and the other end of the copper busbar 36 is connected to the output terminal of the capacitor 34. Each copper busbar 36 is also equipped with a corresponding current sensor 37.

[0023] The aforementioned power module 31 uses an HPD-packaged SiC power module, facilitating platform-based design. The aforementioned capacitor 34 is a film capacitor, selected with a withstand voltage of 900V and a target capacitance of 1000uF. The length, height, and width of capacitor 34 are 337mm, 50mm, and 82mm, respectively. Simulation under current boundary heat dissipation conditions shows a maximum internal cell temperature of 96℃, meeting safety requirements.

[0024] Reference Figure 4 One of the six-phase motor controller assemblies 30 has a shielding plate 38 on its power module 31, and a control board 41 is mounted on the shielding plate. The control board 41 communicates with the vehicle controller (VCU) and is electrically connected to the power module 31 to control the power module 31 to output the corresponding current to the corresponding motor.

[0025] The main housing 10 has two power input interfaces 104 on each side of its rear end face, and a twelve-phase output interface 105 between the power input interfaces 104. The power input interfaces 104 and the output interfaces 105 are staggered. Each DC wire 32 passes through the power input interface 104 into the main housing, and each AC wire 35 passes through the output interface 105. The DC wires 32 and AC wires 35 are installed in the same direction to facilitate the installation of the wiring harness.

[0026] The above are merely specific embodiments of this utility model, but the design concept of this utility model is not limited thereto. Any non-substantial modifications made to this utility model using this concept shall be considered as an infringement of the protection scope of this utility model.

Claims

1. A two-in-one controller based on a six-phase motor controller assembly, characterized in that: The system includes a main housing, cooling water channels, and two sets of six-phase motor controller assemblies. A partition plate in the middle of the main housing divides it into an upper cavity and a lower cavity. Each of the upper and lower cavities houses one set of six-phase motor controller assemblies. The cooling water channels include an inlet, an upper channel, a lower channel, and an outlet. The inlet connects to both the upper and lower channels, and the ends of both channels connect to the outlet. The upper and lower channels are located on the upper and lower sides of the partition plate, respectively. Each six-phase motor controller assembly includes two power modules, two DC power lines, two DC filter components, one capacitor, and six AC power lines. The power modules of the two sets of six-phase motor controller assemblies are respectively located on the outer surfaces of the upper and lower water channels. Each DC wire is connected to the input terminal of the capacitor through a DC filter component. The output terminal of the capacitor is connected to the input terminals of the two power modules. The output terminal of each power module is connected to three AC wires through three copper busbars. Two power input interfaces are respectively provided on both sides of the rear end face of the main housing. A twelve-phase output interface is provided between the power input interfaces. The power input interfaces and the output interfaces are staggered. Each DC wire passes through the power input interface into the main housing, and each AC wire passes through the output interface.

2. The two-in-one controller based on a six-phase motor controller assembly as described in claim 1, characterized in that: One of the six-phase motor controller assemblies has a shielding plate on its power module, and a control board is mounted on the shielding plate. The control board communicates with the vehicle controller (VCU) and is electrically connected to the power module.

3. The two-in-one controller based on a six-phase motor controller assembly as described in claim 1, characterized in that: The rear end face of the main housing is provided with a DC mounting base and an AC mounting base. The DC filter assembly is connected to the DC wiring through the DC mounting base, and the copper busbar is connected to the AC wiring through the AC mounting base. Each copper busbar is also provided with a corresponding current sensor.

4. The two-in-one controller based on a six-phase motor controller assembly as described in claim 1, characterized in that: The two sets of six-phase motor controller assemblies are arranged symmetrically in the upper and lower cavities of the main housing, and the power modules of the two sets of six-phase motor controller assemblies are staggered.

5. A two-in-one controller based on a six-phase motor controller assembly as described in claim 1, characterized in that: The power module uses an HPD-packaged SiC power module.

6. A two-in-one controller based on a six-phase motor controller assembly as described in claim 1, characterized in that: The capacitor is a film capacitor, with a length, height, and width of 337mm, 50mm, and 82mm, respectively.

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