Integrated motor controllers, electrical assemblies, and vehicles.

Abstract

Invention details;

Description

Integrated motor controllers, electric powertrains, and vehicles

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to Chinese patent application No. 202221669903.5 filed by BYD Co., Ltd. on June 30, 2022, entitled “Integrated Motor Controller, Electric Assembly and Vehicle.” Technical Field

[0003] The present disclosure relates to the field of vehicle technology, and in particular to an integrated motor controller, an electric assembly, and a vehicle. Background Art

[0004] In related technologies, vehicles can usually only achieve fast charging of their batteries on DC high-voltage charging piles corresponding to their charging voltage, and there are certain requirements for the charging voltage, resulting in low charging versatility of the vehicle and poor user experience.

[0005] Public content

[0006] The present disclosure aims to address at least one of the technical problems existing in the prior art. To this end, one objective of the present disclosure is to provide an integrated motor controller that is adaptable to various charging voltages, offers advantages such as high versatility and convenient charging. The present disclosure also provides an electric powertrain assembly incorporating such an integrated motor controller.

[0007] According to the present disclosure, a vehicle having the above electric assembly is also provided.

[0008] An integrated motor controller according to an embodiment of the first aspect of the present disclosure includes: a charging connector; a battery connector; a first charging circuit, wherein the first charging circuit is connected to the charging connector and the battery connector respectively, and the first charging circuit has a first control switch, and the first control switch controls the on and off of the first charging circuit; and a second charging circuit, wherein the second charging circuit is connected to the charging connector and the battery connector respectively, and the second charging circuit has a boost module and a second control switch, and the second control switch controls the on and off of the second charging circuit.

[0009] The integrated motor controller according to the embodiment of the present disclosure can be adapted to different charging voltages and has the advantages of high versatility and convenient charging.

[0010] According to some examples of the present disclosure, the integrated motor controller also includes: an AC charge and discharge connector; and an AC charge and discharge circuit, wherein the AC charge and discharge circuit has an on-board charger and a DC converter, the on-board charger is connected to the AC charge and discharge connector, and the DC converter is connected to the battery connector.

[0011] According to some examples of the present disclosure, the charging connector is a DC charging connector; the boost module includes: a motor coil, which is a coil of a driving motor and is connected to the second charging circuit; and an electronically controlled bridge arm, which is a bridge arm of an IGBT module of a motor controller and is connected to the motor coil.

[0012] According to some examples of the present disclosure, the integrated motor controller further includes: a boost capacitor, which is respectively connected to the charging connector, the battery connector and the IGBT module; and a smoothing capacitor, which is respectively connected to the IGBT module and the battery connector.

[0013] According to some examples of the present disclosure, the integrated motor controller further includes a capacitor housing, on which the boost capacitor and the smoothing capacitor are mounted; a battery positive electrode connecting piece, which is mounted on the capacitor housing and is respectively connected to the positive electrode of the battery connector and the positive electrode of the smoothing capacitor; a battery negative electrode connecting piece, which is mounted on the capacitor housing and is respectively connected to the negative electrode of the battery connector and the negative electrode of the smoothing capacitor; an output connecting piece, which is mounted on the capacitor housing and is respectively connected to the smoothing capacitor and the boost module; a charging positive electrode connecting piece, which is mounted on the capacitor housing and is respectively connected to the positive electrode of the charging connector and the boost capacitor; and a charging negative electrode connecting piece, which is mounted on the capacitor housing and is respectively connected to the negative electrode of the charging connector, the boost capacitor and the battery negative electrode connecting piece.

[0014] According to some examples of the present disclosure, the capacitor housing has a first side, a second side, a third side and a fourth side connected end to end along the circumference of the capacitor housing; the battery positive electrode connecting plate, the battery negative electrode connecting plate and the charging negative electrode connecting plate are installed on the first side, the output connecting plate is installed on the second side, and the charging positive electrode connecting plate is installed on the third side.

[0015] According to some examples of the present disclosure, the integrated motor controller further includes: a circuit safety protection component, which is installed on the capacitor housing and is respectively connected to the battery negative electrode connecting plate and the negative electrode of the smoothing capacitor.

[0016] According to some examples of the present disclosure, the integrated motor controller also includes: a charging end magnetic ring, which is installed on the outer circumferential surface of the capacitor housing, the charging connector is connected to the charging positive electrode connector and the charging negative electrode connector through an intermediate connector, and the charging end magnetic ring is sleeved on the intermediate connector; and a battery end magnetic ring, which is installed on the outer circumferential surface of the capacitor housing, and the battery end magnetic ring is sleeved on the battery connector.

[0017] According to some examples of the present disclosure, a heat dissipation metal plate is bonded to the capacitor housing; a thermal conductive mud is bonded to the heat dissipation metal plate on a first surface in a thickness direction thereof and to the box body on a second surface in a thickness direction thereof.

[0018] According to some examples of the present disclosure, the integrated motor controller also includes: a box body, a first cavity is provided on the first side of the box body in the thickness direction, and a second cavity is provided on the second side of the box body in the thickness direction, and the IGBT module is installed in the first cavity; a drive board, the drive board is installed in the first cavity, the drive board is respectively connected to the IGBT modules, a control board, the control board is installed in the first cavity, the control board is connected to the drive board; a power supply power device, the power supply power device is installed in the second cavity and connected to the control board.

[0019] According to some examples of the present disclosure, the box body is provided with a first water channel and a second water channel, the first water channel is suitable for connecting with a water inlet pipe, and the second water channel is suitable for connecting with a water outlet pipe; the integrated motor controller also includes: a water channel cover plate, the water channel cover plate is connected to the box body, and the water channel cover plate covers the first water channel and the second water channel, the water channel cover plate is provided with a third water channel, and the third water channel is respectively connected with the first water channel and the second water channel; wherein, the coolant in the first water channel flows into the third water channel to dissipate heat for the IGBT module, and the coolant in the third water channel flows into the second water channel to dissipate heat for the power supply device.

[0020] According to some examples of the present disclosure, there are multiple IGBT modules; the third water channel includes multiple cooling cavities arranged along the length direction of the third water channel, and the multiple cooling cavities correspond one-to-one to the multiple IGBT modules. Each cooling cavity includes a water inlet and a water outlet, and the adjacent water inlets and water outlets of two adjacent cooling cavities are connected. The first water channel is connected to the water inlet of the cooling cavity adjacent to it, and the second water channel is connected to the water outlet of the cooling cavity adjacent to the second water channel; at least one partition is provided on the side of the water channel cover plate facing the box body, and the partition prevents the adjacent water inlets and water outlets from being connected to the second water channel.

[0021] According to some examples of the present disclosure, the second water channel includes: a transition section, which is connected to the water outlet of the cooling cavity adjacent to the transition section; and an annular section, which surrounds the power supply device and dissipates heat for the power supply device, wherein the first end of the annular section is connected to one end of the transition section, and the second end of the annular section is provided with a water outlet hole; wherein the depth of the annular section is greater than the depth of the first water channel, and the depth of the annular section is greater than the depth of the transition section.

[0022] According to some examples of the present disclosure, the integrated motor controller also includes: a water inlet pipe, which is installed on the box body and connected to the first water channel; a water outlet pipe, which is installed on the box body and connected to the water outlet hole, and the water outlet pipe and the water inlet pipe are arranged vertically.

[0023] According to some examples of the present disclosure, the integrated motor controller includes: a charging connector for connecting a charging device; a battery connector for connecting a battery pack; a first charging circuit, the first charging circuit being connected to the charging connector and the battery connector respectively; and a second charging circuit, the second charging circuit being connected to the charging connector and the battery connector respectively, the second charging circuit having a boost module; wherein one of the first charging circuit and the second charging circuit is selectively turned on.

[0024] According to some examples of the present disclosure, when the voltage provided by the charging device is higher than a preset value, the first charging circuit is turned on; when the voltage provided by the charging device is not higher than the preset value, the second charging circuit is turned on.

[0025] According to some examples of the present disclosure, the boost module includes a motor coil and an electrically controlled bridge arm, the motor coil includes three groups, the electrically controlled bridge arm includes a three-phase bridge arm, the first ends of the three groups of motor coils are respectively connected to the midpoints of the three-phase bridge arms, and the second ends of the three groups of motor coils are all connected to the charging connector.

[0026] According to an electric assembly according to an embodiment of the second aspect of the present disclosure, the electric assembly includes: an integrated motor controller according to the embodiment of the first aspect of the present disclosure.

[0027] According to the electric assembly of the embodiment of the present disclosure, by adopting the above-mentioned integrated motor controller, it can be adapted to different charging voltages and has the advantages of high versatility and convenient charging.

[0028] According to a vehicle according to an embodiment of the third aspect of the present disclosure, the vehicle includes an electric assembly according to an embodiment of the second aspect of the present disclosure.

[0029] The vehicle according to the embodiment of the present disclosure, by adopting the above-mentioned electric assembly, can be adapted to different charging voltages, and has the advantages of high versatility and convenient charging.

[0030] Additional aspects and advantages of the present disclosure will be given in part in the description that follows and, in part, will be obvious from the description that follows, or will be learned through practice of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The above and / or additional aspects and advantages of the present disclosure will become apparent and readily understood from the description of the embodiments in conjunction with the following drawings, in which:

[0032] FIG1 is a schematic diagram of an integrated motor controller according to an embodiment of the present disclosure.

[0033] FIG2 is a schematic structural diagram of an electric assembly according to an embodiment of the present disclosure.

[0034] FIG3 is an exploded view of an integrated motor controller according to an embodiment of the present disclosure;

[0035] FIG. 4 is another exploded view of an integrated motor controller according to an embodiment of the present disclosure.

[0036] FIG5 is a cross-sectional view of an integrated motor controller according to an embodiment of the present disclosure.

[0037] FIG6 is a schematic structural diagram of a capacitor housing according to an embodiment of the present disclosure.

[0038] FIG7 is a schematic structural diagram of a box according to an embodiment of the present disclosure.

[0039] FIG8 is a structural schematic diagram of the box from another perspective according to an embodiment of the present disclosure.

[0040] FIG9 is a schematic structural diagram of a waterway cover plate according to an embodiment of the present disclosure,

[0041] FIG10 is a cross-sectional view of a waterway cover plate according to an embodiment of the present disclosure;

[0042] FIG. 11 is a schematic diagram of a vehicle according to an embodiment of the present disclosure.

[0043] Reference numerals:

[0044] 1. Integrated motor controller; 2. Electric assembly; 3. Transmission; 4. Vehicle;

[0045] 100, charging connector; 110, battery connector; 120, intermediate connector; 200, first charging circuit; 210, first control switch; 300, second charging circuit; 310, boost module; 311, drive motor; 312, motor coil; 313, motor controller; 315, IGBT module; 316, electronically controlled bridge arm; 320, second control switch; 400, AC charging and discharging connector; 410, AC charging and discharging circuit; 411, on-board charger; 412, DC converter; 420, in-vehicle discharge connector; 5 00, capacitor housing; 501, first side; 502, second side; 503, third side; 504, fourth side; 505, wiring harness fixing slot; 506, tie hole; 510, battery positive terminal connection plate; 520, battery negative terminal connection plate; 530, output terminal connection plate; 540, charging positive terminal connection plate; 550, charging negative terminal connection plate; 590, negative input terminal; 591, heat dissipation metal plate; 592, thermal paste; 5921, first surface; 5922, second surface; 593, magnetic ring mounting position; 600, circuit safety protection component; 610, charging end magnetic ring; 620, battery end magnetic ring; 630, smoothing capacitor; 640, boost capacitor; 700, housing; 701, first side; 702, second side; 710, first chamber; 711, second water channel; 712, first water channel; 713, transition section; 714, annular section; 715, first end; 716, second end; 717, water outlet; 720, second chamber; 730, drive board; 740, control board; 750, power device; 760, upper cover; 770, lower cover; 800, water channel cover; 810, third water channel; 811, cooling chamber; 812, water inlet; 813, water outlet; 820, partition; 840, sealing groove; 900, water inlet pipe; 910, water outlet pipe; 911, pressure plate. DETAILED DESCRIPTION

[0046] The following describes in detail embodiments of the present disclosure, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended only to explain the present disclosure and are not to be construed as limiting the present disclosure.

[0047] In the description of the present disclosure, it should be understood that the terms "center", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the present disclosure 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, and therefore cannot be understood as a limitation on the present disclosure.

[0048] It should be noted that the terms "first" and "second" are used for descriptive purposes only and should not be understood to indicate or imply relative importance or implicitly specify the number of the technical features indicated. Therefore, features defined as "first" or "second" may explicitly or implicitly include one or more of the features. Furthermore, in the description of this disclosure, unless otherwise specified, "plurality" means two or more.

[0049] An integrated motor controller 1 according to an embodiment of the present disclosure will be described below with reference to the accompanying drawings.

[0050] As shown in FIG. 1 to FIG. 10 , the integrated motor controller 1 according to an embodiment of the present disclosure includes a charging connector 100 , a battery connector 110 , a first charging circuit 200 , and a second charging circuit 300 .

[0051] The first charging circuit 200 is connected to the charging connector 100 and the battery connector 110 respectively. The first charging circuit 200 has a first control switch 210, which controls the on and off of the first charging circuit 200. The second charging circuit 300 is connected to the charging connector 100 and the battery connector 110 respectively. The second charging circuit 300 has a boost module 310 and a second control switch 320, which controls the on and off of the second charging circuit 300.

[0052] For example, the first control switch 210 and the second control switch 320 may be contactors, and the charging connector 100 and the battery connector 110 may be plug connectors. Furthermore, the charging connector 100 may be connected to an external charging device, for example, the charging connector 100 may be connected to a charging station, and the battery connector 110 may be connected to a vehicle's battery pack.

[0053] According to the integrated motor controller 1 of the embodiment of the present disclosure, by connecting the first charging circuit 200 to the charging connector 100 and the battery connector 110 respectively, the first charging circuit 200 has a first control switch 210 for controlling the on and off of the first charging circuit 200. In this way, when the charging connector 100 is connected to a charging device with a higher voltage (a voltage not less than 750V), for example, when the charging connector 100 is connected to a charging device with a charging voltage of 750V, the first control switch 210 can be in a connected state, so that the current can directly charge the battery connector 110 through the first charging circuit 200, thereby realizing fast charging of the battery pack.

[0054] In addition, the second charging circuit 300 is connected to the charging connector 100 and the battery connector 110 respectively. The second charging circuit 300 has a boost module 310 and a second control switch 320 for controlling the on and off of the second charging circuit 300. In this way, when the charging connector 100 is connected to a charging device with a lower voltage (voltage lower than 750V), for example, when the charging connector 100 is connected to a charging device with a charging voltage of 470V, the second control switch 320 can be in a connected state so that current can flow through the second charging circuit 300, and the boost module 310 can boost the voltage of the second charging circuit 300 so that the voltage of the second charging circuit 300 can be boosted to above 630V, thereby quickly charging the battery pack.

[0055] Moreover, when the charging connector 100 is not connected to a charging device, both the first control switch 210 and the second control switch 320 can be in the disconnected state; when the charging connector 100 is connected to a charging device, the integrated motor controller 1 can detect the output voltage of the charging device. If the charging voltage is high, the first control switch 210 is connected and the second control switch 320 is disconnected, and the charging device can directly charge the battery pack through the first charging circuit 200; if the charging voltage is low, the second control switch 320 is connected and the first control switch 210 is disconnected, and the charging device can charge the battery after boosting the voltage through the boost module 310 of the second charging circuit 300.

[0056] In this way, the first control switch 210 and the second control switch 320 are generally not closed at the same time, so as to reduce voltage fluctuations during charging and help maintain the stability of the charging voltage. Moreover, by controlling the closing and opening of the first control switch 210 and the second control switch 320, the charging connector 100 can be connected to the battery connector 110 through different charging circuits to ensure that the charging voltage is large enough to achieve rapid charging of the battery pack, while also preventing the battery pack from being damaged by excessive charging voltage, thereby improving safety. Therefore, the integrated motor controller 1 of the embodiment of the present disclosure is applicable to a variety of charging devices and can achieve rapid charging of the battery pack regardless of the output voltage of the charging device, making charging more convenient and time-saving.

[0057] In this way, the integrated motor controller 1 according to the embodiment of the present disclosure can be applicable to different charging voltages, and has the advantages of high versatility and convenient charging.

[0058] In some specific embodiments of the present disclosure, as shown in FIG. 1 , the integrated motor controller 1 further includes an AC charge and discharge connector 400 and an AC charge and discharge circuit 410 .

[0059] The AC charge and discharge circuit 410 includes an on-board charger (OBC) 411 and a DC / DC converter 412 . The OBC 411 is connected to the AC charge and discharge connector 400 , and the DC / DC converter 412 is connected to the battery connector 110 .

[0060] The onboard charger 411 can dynamically adjust the charging voltage and current parameters based on the required charging current and voltage of the battery pack, facilitating charging and protecting the battery pack. Furthermore, the onboard charger 411 can be connected to an in-vehicle discharge connector 420 to charge items that passengers require AC charging.

[0061] In this way, AC power can be connected through the AC charging and discharging connector 400, and the battery can be charged by AC power. The on-board charger 411 can adjust the parameters of the AC voltage, change the size of the charging voltage and convert AC power into DC power at the same time, so as to facilitate charging the battery pack.

[0062] Furthermore, the DC converter 412 stabilizes the voltage and current of the DC power passing through the onboard charger 411, converting low-voltage charging current into high-voltage charging current for rapid charging of the battery pack. Furthermore, the battery pack can transmit AC power to the AC charging and discharging connector 400 via the AC charging and discharging circuit 410, allowing the AC charging and discharging connector 400 to power AC-powered electrical appliances in the vehicle.

[0063] In some specific embodiments of the present disclosure, the charging connector 100 is a DC charging connector 100 , and the boost module 310 includes a motor coil 312 and an electronically controlled bridge arm 316 .

[0064] The motor coil 312 is the coil that drives the motor 311 and is connected to the second charging circuit 300. The electrically controlled bridge arm 316 is the bridge arm of the IGBT module 315 of the motor controller 313 and is connected to the motor coil 312. In this way, the current passing through the second charging circuit 300 can flow sequentially through the motor coil 312 and the electrically controlled bridge arm 316. The motor coil 312 and the electrically controlled bridge arm 316 form the boost module 310, which increases the voltage of the second charging circuit 300 and achieves rapid charging of the battery.

[0065] In this way, the boost module 310 and the motor controller 313 share the bridge arm of the IGBT module 315 of the motor controller 313, and the boost module 310 and the drive motor 311 share the motor coil 312. There is no need to set up additional electronic components such as inductors, diodes, and switching devices, which reduces the number of parts and reduces production costs, thereby helping to reduce the volume of the electric assembly 2.

[0066] Moreover, since the drive motor 311 is generally a three-phase motor, that is, the motor coils 312 of the drive motor 311 are three groups, by applying the three groups of motor coils 312 of the drive motor 311 to the boost module 310, the probability of ripple current generated by the second charging circuit 300 can be reduced, further ensuring the stability of the input voltage of the battery pack.

[0067] In some specific embodiments of the present disclosure, the integrated motor controller 1 further includes a boost capacitor 640 and a smoothing capacitor 630 .

[0068] Boost capacitor 640 is connected to charging connector 100, battery connector 110, and IGBT module 315, respectively. Smoothing capacitor 630 is connected to IGBT module 315 and battery connector 110, respectively. When the battery pack supplies power to IGBT module 315 for vehicle driving, the battery pack current first passes through smoothing capacitor 630, absorbing ripple current and current energy in the current flowing to battery connector 110. This allows filtering and maintains voltage and current stability when the battery pack supplies power to IGBT module 315. During boost charging, the boosted current from motor coil 312 flows through IGBT module 315 and then into smoothing capacitor 630. Smoothing capacitor 630 absorbs the boosted circuit ripple current and current energy, ensuring voltage stability when the charging current flows to the battery pack.

[0069] This maintains a stable voltage at the battery connector 110, thereby maintaining stable charging and discharging voltages for the battery pack. However, the smoothing capacitor 630 and the motor coil form an L / C circuit. The boost capacitor 640 absorbs ripple current in the current input from the charging connector 100, filtering the current input from the charging connector 100 and stabilizing the voltage of the current input from the charging connector 100.

[0070] In some specific embodiments of the present disclosure, as shown in Figure 6, the integrated motor controller 1 also includes a capacitor housing 500, a battery positive electrode connecting plate 510, a battery negative electrode connecting plate 520, an output connecting plate 530, a charging positive electrode connecting plate 540 and a charging negative electrode connecting plate 550.

[0071] The boost capacitor 640 and the smoothing capacitor 630 are installed in the capacitor housing 500, the battery positive connecting piece 510 is installed in the capacitor housing 500, and the battery positive connecting piece 510 is respectively connected to the positive electrode of the battery connector 110 and the positive electrode of the smoothing capacitor 630, the battery negative connecting piece 520 is installed in the capacitor housing 500, and the battery negative connecting piece 520 is connected to the negative electrode of the battery connector 110 and the negative electrode of the smoothing capacitor 630, the output connecting piece 530 is installed in the capacitor housing 500, and The output connecting piece 530 is respectively connected to the smoothing capacitor 630 and the IGBT module 315, the charging positive connecting piece 540 is installed on the capacitor housing 500, and the charging positive connecting piece 540 is connected to the positive electrode of the charging connector 100 and the boost capacitor 640, the charging negative connecting piece 550 is installed on the capacitor housing 500, and the charging negative connecting piece 550 is respectively connected to the negative electrode of the charging connector 100, the boost capacitor 640, the smoothing capacitor 630 and the battery negative connecting piece 520.

[0072] For example, to enhance heat dissipation from the boost capacitor 640 and the smoothing capacitor 630, the capacitor housing 500 includes a heat dissipation metal plate 591 and a thermal paste 592. The heat dissipation metal plate 591 is bonded to the capacitor housing 500, a first surface 5921 of the thermal paste 592 is bonded to the heat dissipation metal plate 591, and a second surface 5922 of the thermal paste 592 is bonded to the electrical control housing. In other words, the thermal paste 592 is positioned between the heat dissipation metal plate 591 and the electrical control housing, allowing heat from the capacitors to be transferred to the electrical control housing through the thermal paste 592, dissipating heat from the capacitors. To facilitate wiring harness routing, the capacitor housing 500 may also include features such as a harness securing slot 505 and a tie hole 506.

[0073] The boost capacitor 640 and the smoothing capacitor 630 can be integrated into the capacitor housing 500, which is convenient for arrangement and saves assembly space. Thus, the capacitor housing 500 can fix the battery positive connecting piece 510, the battery negative connecting piece 520, the output connecting piece 530, the charging positive connecting piece 540 and the charging negative connecting piece 550, and the battery positive connecting piece 510, the battery negative connecting piece 520, the output connecting piece 530, the charging positive connecting piece 540 and the charging negative connecting piece 550 can be exposed from the capacitor housing 500, so as to facilitate the connection of the battery pack and the smoothing capacitor 630, as well as the connection of the boost capacitor 640 and the charging connector 100, so that the connection is more reliable and the assembly efficiency is higher.

[0074] In some specific embodiments of the present disclosure, as shown in Figure 6, the capacitor housing 500 has a first side 501, a second side 502, a third side 503 and a fourth side 504 connected end to end along the circumference of the capacitor housing 500, the battery positive electrode connecting plate 510, the battery negative electrode connecting plate 520 and the charging negative electrode connecting plate 550 are installed on the first side 501, the output connecting plate 530 is installed on the second side 502, and the charging positive electrode connecting plate 540 is installed on the third side 503.

[0075] In this way, the battery positive connecting piece 510, the battery negative connecting piece 520 and the charging negative connecting piece 550 can be separated from the output connecting piece 530 and the charging positive connecting piece 540 to avoid positional interference between multiple components and facilitate installation. At the same time, it can prevent multiple components from short-circuiting when connected to the power supply and maintain circuit connectivity.

[0076] In some specific embodiments of the present disclosure, as shown in FIG. 5 , the integrated motor controller 1 further includes a circuit safety protection component 600 .

[0077] The circuit safety protection component 600 is installed on the capacitor housing 500, and the circuit safety protection component 600 is respectively connected to the battery negative electrode connecting piece 520 and the negative electrode of the smoothing capacitor 630. For example, the circuit safety protection component 600 can be a fuse. The integrated motor controller 1 also includes a negative electrode input piece 590. The two ends of the circuit safety protection component 600 are respectively connected to the negative electrode input piece 590 and the battery negative electrode connecting piece 520. The battery negative electrode connecting piece 520 is connected to the negative electrode of the smoothing capacitor 630. The battery negative electrode connecting piece 520 is connected to the negative electrode of the smoothing capacitor 630 through the circuit safety protection component 600 and the negative electrode input piece 590, wherein the battery negative electrode connecting piece 520 is installed on the first side 501.

[0078] Therefore, when the current passing through the battery negative electrode connecting plate 520 and the current of the smoothing capacitor 630 are too large, causing overcurrent in the circuit and rising temperature, the circuit safety protection component 600 can be disconnected to cut off the current in the circuit, thereby avoiding damage to the battery pack and helping to improve the safety of the battery pack during charging and discharging.

[0079] In some specific embodiments of the present disclosure, as shown in FIG. 4 , the integrated motor controller 1 further includes a charging-end magnetic ring 610 and a battery-end magnetic ring 620 .

[0080] The charging end magnetic ring 610 is installed on the outer circumference of the capacitor housing 500, and the charging connector 100 is connected to the charging positive electrode connector 540 and the charging negative electrode connector 550 through the intermediate connector 120. The charging end magnetic ring 610 is sleeved on the intermediate connector 120, and the battery end magnetic ring 620 is installed on the outer circumference of the capacitor housing 500. The battery end magnetic ring 620 is sleeved on the battery connector 110.

[0081] In this way, the charging end magnetic ring 610 can block the external electromagnetic interference to the intermediate connector 120, and the battery end magnetic ring 620 can block the external electromagnetic interference to the battery connector 110, thereby avoiding the external electromagnetic interference to the battery and making the voltage of the battery pack more stable during charging and discharging.

[0082] Moreover, the capacitor housing 500 can be provided with a magnetic ring mounting position 593 for mounting the battery end magnetic ring 620, so that both the charging end magnetic ring 610 and the battery end magnetic ring 620 can be integrated into the capacitor housing 500, thereby improving the integration of the capacitor housing 500, making the structure of the capacitor housing 500 more compact, saving assembly space, and the capacitor housing 500 has a better anti-electromagnetic interference effect.

[0083] The working process of the integrated motor controller 1 is described with examples in conjunction with the accompanying drawings:

[0084] When the battery pack supplies power to the drive motor, the current from the battery pack passes through the battery connector 110. The positive electrode of the battery connector 110 flows to the smoothing capacitor 630 through the positive battery connector 510, and then supplies power to the IGBT module 315 via the output connector 530. After being converted into AC power by the IGBT module 315, it flows to the drive motor 311. The negative electrode of the battery connector 110 flows through the negative battery connector 520, the circuit safety protection component 600, and the negative input plate 590 to the smoothing capacitor 630. After that, it supplies power to the IGBT module 315 via the output connector 530, and after being converted into AC power by the IGBT module 315, it flows to the drive motor 311.

[0085] When charging the battery pack and the charging voltage is less than 750V: the charging current passes through the charging connector 100 and the charging end magnetic ring 610, and then the negative pole of the charging connector 100 flows through the charging negative pole connecting piece 550 to the battery negative pole connecting piece 520, and then flows to the battery pack through the battery connector 110; the positive pole of the charging connector 100 flows to the motor coil 312 and the IGBT module 315, and is boosted at the motor coil 312. The boosted current flows to the battery positive pole connecting piece 510, and then flows to the battery pack through the battery connector 110.

[0086] In some specific embodiments of the present disclosure, as shown in FIG. 3 , FIG. 4 , FIG. 7 and FIG. 8 , the integrated motor controller 1 further includes a housing 700 , a driving board 730 , a control board 740 and a power supply device 750 .

[0087] A first chamber 710 is defined on a first side 701 of the housing 700 in the thickness direction, and a second chamber 720 is defined on a second side 702 of the housing 700 in the thickness direction. The IGBT module 315 is mounted in the first chamber 710. A drive board 730 and a control board 740 are mounted in the first chamber 710. The drive board 730 is connected to the IGBT module 315 and the control board 740, respectively. A power supply device 750 is mounted in the second chamber 720 and is connected to the control board 740. The control board 740 is connected to the vehicle controller.

[0088] That is to say, the first chamber 710 and the second chamber 720 are respectively arranged on both sides of the thickness direction of the box body 700. In this way, the side wall between the first chamber 710 and the second chamber 720 can separate the IGBT module 315, the drive board 730, and the control board 740 from the power supply device 750, effectively reducing the electromagnetic interference of the power supply device 750 on the IGBT module 315, the drive board 730 and the control board 740, thereby improving the effectiveness of the electronic control. Moreover, the IGBT module 315, the drive board 730, the control board 740 and the power supply device 750 can all be integrated into the box body 700, and the box body 700 can fix the IGBT module 315, the drive board 730, the control board 740 and the power supply device 750. The structure is more compact, which is conducive to reducing the overall volume of the integrated motor controller 1 and facilitating installation.

[0089] Of course, the first chamber 710 can be divided into multiple small chambers, and the second chamber 720 can also be divided into multiple small chambers. The power supply device 750 is provided with an AC inductor, a DC inductor, a MOS tube and an inductor transformer. The AC inductor, the DC inductor, the MOS tube and the inductor transformer are placed in the small chamber of the second chamber 720. This further avoids electromagnetic interference between multiple power modules and is conducive to improving electromagnetic compatibility.

[0090] In addition, a wire hole may be provided between the first chamber 710 and the second chamber 720, and a wiring harness may pass through the wire hole to connect the electrical components in the first chamber 710 with the electrical components in the second chamber 720, so as to facilitate electrical connection between the components in the first chamber 710 and the components in the second chamber 720.

[0091] For example, the control board 740 , the driving board 730 and the IGBT module 315 are stacked in sequence, and an electromagnetic shielding plate is provided between the control board 740 and the driving board 730 to prevent the IGBT module 315 from interfering with the control board 740 when working.

[0092] Among them, the integrated motor controller 1 can be provided with an upper cover 760 and a lower cover 770. The upper cover 760 can be used to cover the first chamber 710, thereby protecting the components in the first chamber 710, such as the IGBT module 315, the drive board 730 and the control board 740, to avoid positional interference between external components and the IGBT module 315, the drive board 730 and the control board 740, etc. At the same time, the lower cover 770 can be used to cover the second chamber 720, thereby protecting the power supply device 750, thereby avoiding positional interference between other components and the power supply device 750.

[0093] In some specific embodiments of the present disclosure, as shown in Figures 9 and 10, the integrated motor controller 1 further includes a water channel cover plate 800. The water channel cover plate 800 can be integrally connected to the box body 700 by friction welding.

[0094] The water channel cover 800 is provided with a third water channel 810, and the housing 700 is provided with a first water channel 712 and a second water channel 711. The water channel cover 800 is connected to the housing 700 and covers the first and second water channels 712, 711. The third water channel 810 is in communication with the first and second water channels 712, 711, respectively. Coolant in the first water channel 712 flows into the third water channel 810 to dissipate heat for the IGBT module 315, while coolant in the third water channel 810 flows into the second water channel 711 to dissipate heat for the power device 750.

[0095] That is to say, the third water channel 810, the first water channel 712 and the second water channel 711 form a connected water channel, and the coolant in the third water channel 810, the first water channel 712 and the second water channel 711 can be shared, that is, the coolant in the third water channel 810, the first water channel 712 and the second water channel 711 can circulate with each other, and the IGBT module 315 can seal the third water channel 810 to avoid leakage of the coolant in the third water channel 810, the first water channel 712 and the second water channel 711, and the coolant in the third water channel 810 can cool the IGBT module 315 to avoid damage to the IGBT module 315 by high temperature, and at the same time keep the IGBT module 315 in a low temperature state to maintain its working stability.

[0096] In addition, the first water channel 712 and the second water channel 711 can be sealed by the water channel cover 800 to prevent the coolant in the first water channel 712 and the second water channel 711 from leaking, and the coolant in the second water channel 711 can exchange heat with the power supply device 750 through the outer wall of the second water channel 711, thereby reducing the temperature of the power supply device 750 and keeping the power supply device 750 in a low temperature state, thereby improving the working stability of the power supply device 750 and preventing high temperature from damaging the power supply device 750.

[0097] Moreover, the third water channel 810, the first water channel 712 and the second water channel 711 are connected, and the flow path of the coolant is longer. The coolant in the first water channel 712 can flow into the third water channel 810 to dissipate heat for the IGBT module 315, and the coolant in the third water channel 810 can also flow into the second water channel 711 to dissipate heat for the power device 750, which is beneficial to improving the utilization rate of the coolant and allowing the coolant to fully exchange heat with the power device 750 and the IGBT module 315.

[0098] Furthermore, as shown in FIG9 , the third water channel 810 includes a plurality of cooling cavities 811 arranged along its length direction, and there are multiple IGBT modules 315, and the multiple cooling cavities 811 correspond one-to-one to the multiple IGBT modules 315. In this way, each cooling cavity 811 can perform heat exchange for the IGBT module 315 corresponding thereto, and further dissipate heat for the IGBT module 315. The water channel cover plate 800 is provided with a sealing groove 840 surrounding the water channel cover plate 800, and a sealing ring is provided in the sealing groove 840. The sealing ring fills the gap between the IGBT module 315 and the water channel cover plate 800. Each IGBT module 315 can better seal the cooling cavity 811 corresponding thereto, thereby ensuring the sealing of the third water channel 810 and preventing leakage of the coolant in the cooling cavity 811.

[0099] In addition, each cooling chamber 811 includes a water inlet 812 and a water outlet 813, and the adjacent water inlets 812 and water outlets 813 of two adjacent cooling chambers 811 are connected. The first water channel 712 is connected to the water inlet 812 of the cooling chamber 811 adjacent to it, and the second water channel 711 is connected to the water outlet 813 of the cooling chamber 811 adjacent to it. At least one partition 820 is provided on the side of the water channel cover 800 facing the box body 700, and the partition 820 prevents the adjacent water inlet 812 and water outlet 813 from being connected to the second water channel 711.

[0100] That is to say, the partition 820 can separate the second water channel 711 and the third water channel 810, and the coolant in the adjacent cooling chambers 811 can be kept connected through the water inlet 812 and the water outlet 813, so that the coolant in the third water channel 810 can flow through all the cooling chambers 811, avoiding the coolant flowing directly to the second water channel 711 and causing some cooling chambers 811 to have no coolant, which is beneficial to improving the cooling effect of the third water channel 810 on the IGBT module 315, so that multiple IGBT modules 315 can stably exchange heat with the cooling chamber 811.

[0101] For example, one of the two outermost cooling cavities 811 can be connected to the second water channel 711 through the water outlet 813, and the other of the two cooling cavities 811 can be connected to the first water channel 712 through the water inlet 812. In this way, the coolant in the first water channel 712 can enter the third water channel 810 through the water inlet 812 of the outermost cooling cavity 811, and flow back to the second water channel 711 through the water outlet 813 of the other cooling cavity 811, thereby realizing the circulation of the coolant in the first water channel 712, the third water channel 810 and the second water channel 711, and the coolant can completely flow through the second water channel 711 and the third water channel 810, which is beneficial to improving the utilization rate of the coolant.

[0102] In some specific embodiments of the present disclosure, as shown in FIG. 7 , the second water channel 711 includes a transition section 713 and an annular section 714 .

[0103] The transition section 713 is connected to the water outlet 813 of the adjacent cooling chamber 811. The annular section 714 surrounds the power device 750 and dissipates heat for the power device 750. The first end 715 of the annular section 714 is connected to one end of the transition section 713, and the second end 716 of the annular section 714 is provided with a water outlet hole 717. The outer wall of the annular section 714 dissipates heat for the power device 750.

[0104] Thus, the coolant first flows into the first water channel 712, and then flows into the cooling cavity 811 adjacent to the first water channel 712. Then, the coolant in the third water channel 810 flows through multiple cooling cavities 811 in sequence along the direction from the first water channel 712 to the transition section 713. Next, the coolant flows from the cooling cavity 811 adjacent to the transition section 713 to the transition section 713, and finally flows from the transition section 713 to the annular section 714, and is discharged from the water outlet 717 of the annular section 714.

[0105] In addition, the contact area between the annular segment 714 and the power device 750 is larger, and the structure of the annular segment 714 is more compact, occupying less space. Using the annular segment 714 to dissipate heat for the power device 750 can improve the heat exchange effect between the second water channel 711 and the power device 750, thereby enabling the power device 750 to cool down quickly and achieve better heat dissipation effect.

[0106] In addition, the depth of the annular section 714 is greater than the depth of the first water channel 712 and the depth of the transition section 713. This can, on the one hand, make the volume of the annular section 714 larger, and the amount of coolant in the annular section 714 can be more, thereby improving the heat dissipation effect of the annular section 714 on the power device 750. On the other hand, it can make the transition between the first water channel 712 and the third water channel 810 smoother, and the transition between the transition section 713 and the third water channel 810 smoother, and the coolant circulates more smoothly between the second water channel 711 and the third water channel 810, so that the coolant can fully exchange heat with the power device 750 and the IGBT module 315, further improving the heat dissipation effect of the power device 750 and the heat dissipation effect of the IGBT module 315.

[0107] For example, the ring segment 714 is in a "U" shape and surrounds the inductor transformer of the power device 750 to dissipate heat. The MOS tube, AC inductor and DC inductor of the power device 750 are located outside the "U"-shaped ring segment 714 and are in contact with the outer wall of the ring segment 714.

[0108] In some specific embodiments of the present disclosure, as shown in FIG. 7 and FIG. 8 , the integrated motor controller 1 further includes a water inlet pipe 900 and a water outlet pipe 910 .

[0109] The water inlet pipe 900 is installed in the box body 700 and is connected to the first water channel 712. The water outlet pipe 910 is installed in the box body 700 and is connected to the water outlet hole 717. In this way, the coolant can flow into the first water channel 712, the third water channel 810 and the second water channel 711 through the water inlet pipe 900, and the coolant can be discharged through the water outlet hole 717 and the water outlet pipe 910. That is to say, after the coolant has fully exchanged heat with the power device 750 and the IGBT module 315, the first water channel 712, the third water channel 810 and the second water channel 711 are discharged. The coolant in the third water channel 810 and the second water channel 711 can be discharged through the water outlet pipe 910, and the coolant can be replenished to the first water channel 712, the third water channel 810 and the second water channel 711 through the water inlet pipe 900, so as to keep the coolant in the first water channel 712, the third water channel 810 and the second water channel 711 sufficient and the temperature of the coolant low, so as to improve the cooling effect of the second water channel 711 and the third water channel 810 on the power device 750 and the IGBT module 315.

[0110] In addition, the water inlet pipe 900 and the water outlet pipe 910 are arranged vertically. For example, the water inlet pipe 900 can be arranged on one side of the box body 700 and the water outlet pipe 910 can be arranged on the adjacent side of the box body 700. In this way, the position interference of the water inlet pipe 900 and the water outlet pipe 910 can be avoided, which is convenient for layout. The lengths of the second water channel 711 and the third water channel 810 can be set longer so that the second water channel 711 and the third water channel 810 can cover most of the box body 700, further improving the cooling effect of the second water channel 711 and the third water channel 810 on the power device 750 and the IGBT module 315. At the same time, the coolant in the second water channel 711 and the third water channel 810 can reduce the temperature of the box body 700, and can also dissipate heat for other components installed in the box body 700, thereby improving the heat dissipation effect of the box body 700.

[0111] For example, since the above arrangement makes the water outlet pipe 910 longer, a pressure plate 911 can be added. The pressure plate 911 is installed on the box body 700 and clamps the water outlet pipe 910 together with the box body 700 to fix the position of the water outlet pipe 910 relative to the box body 700.

[0112] An integrated motor controller 1 according to another embodiment of the present disclosure includes a charging connector 100 , a battery connector 110 , a first charging circuit 200 , and a second charging circuit 300 .

[0113] The charging connector 100 is used to connect to a charging device, for example, a charging station. The battery connector 110 is used to connect to a battery pack. The first charging circuit 200 is connected to the charging connector 100 and the battery connector 110 respectively. The second charging circuit 300 is connected to the charging connector 100 and the battery connector 110 respectively. The second charging circuit 300 includes a boost module 310. Either the first charging circuit 200 or the second charging circuit 300 is electrically conductive.

[0114] Among them, by connecting the first charging circuit 200 to the charging connector 100 and the battery connector 110 respectively, when the charging connector 100 is connected to a charging device with a higher voltage (voltage not less than 750V), for example, when the charging connector 100 is connected to a charging device with a charging voltage of 750V, the first charging circuit 200 is in an on state, so that the current can directly charge the battery connector 110 through the first charging circuit 200, thereby realizing fast charging of the battery pack.

[0115] In addition, the second charging circuit 300 is connected to the charging connector 100 and the battery connector 110 respectively, and the second charging circuit 300 has a boost module 310. In this way, when the charging connector 100 is connected to a charging device with a lower voltage (voltage lower than 750V), for example, when the charging connector 100 is connected to a charging device with a charging voltage of 470V, the second charging circuit 300 is in an on state, and the boost module 310 can boost the voltage of the second charging circuit 300 so that the voltage of the second charging circuit 300 can be boosted to above 630V, thereby quickly charging the battery pack.

[0116] In this way, the integrated motor controller 1 according to the embodiment of the present disclosure can be applicable to different charging voltages, and has the advantages of high versatility and convenient charging.

[0117] In some embodiments of the present disclosure, when the voltage provided by the charging device is higher than a preset value, the first charging circuit (200) is turned on. At this time, the first charging circuit 200 is turned on and the second charging circuit 300 is disconnected. The charging device can directly charge the battery pack through the first charging circuit 200. When the voltage provided by the charging device is not higher than the preset value, the second charging circuit 300 is turned on. At this time, the second charging circuit 300 is turned on and the first charging circuit 200 is disconnected. The charging device can charge the battery after boosting the voltage through the boost module 310 of the second charging circuit 300. In addition, when the charging connector 100 is not connected to the charging device, the first charging circuit 200 and the second charging circuit 300 are both in the disconnected state.

[0118] In some specific embodiments of the present disclosure, the boost module 310 includes motor coils 312 and an electrically controlled bridge arm 316. The motor coils 312 include three groups, and the electrically controlled bridge arm 316 includes a three-phase bridge arm. The first ends of the three groups of motor coils 312 are respectively connected to the midpoints of the three-phase bridge arms, and the second ends of the three groups of motor coils 312 are all connected to the charging connector 100. In this way, the current passing through the second charging circuit 300 can flow sequentially through the motor coils 312 and the three-phase bridge arm. The motor coils 312 and the three-phase bridge arm form the boost module 310, which boosts the current of the second charging circuit 300 and achieves rapid charging of the battery. Specifically, by having the boost module 310 include three groups of motor coils 312 and a three-phase bridge arm, the probability of ripple current generated by the second charging circuit 300 can be reduced, further ensuring the stability of the input voltage of the battery pack.

[0119] The following describes an electric assembly 2 according to an embodiment of the second aspect of the present disclosure with reference to the accompanying drawings. The electric assembly 2 includes an integrated motor controller 1 according to an embodiment of the first aspect of the present disclosure.

[0120] Specifically, referring to FIG1 , electric assembly 2 also includes a drive motor 311 and a transmission 3. The water outlet pipe 910 of the integrated motor controller 1 can communicate with the coolant channel of the transmission 3. In this way, the coolant in the water channel of the integrated motor controller 1 can dissipate heat from the IGBT module 315 and the power device 750 before flowing to the coolant channel of the transmission 3 to dissipate heat from the drive motor 311 and the transmission 3. The three-phase output terminals of the drive motor 311 are connected to the IGBT module 315, and the coil of the drive motor 311 is connected to the charging connector 100.

[0121] According to the embodiment of the present disclosure, the electric assembly 2 can be adapted to different charging voltages by adopting the above-mentioned integrated motor controller 1, and has the advantages of high versatility and convenient charging.

[0122] As shown in FIG11 , a vehicle 3 according to an embodiment of the third aspect of the present disclosure includes an electric assembly according to an embodiment of the second aspect of the present disclosure.

[0123] According to the embodiment of the present disclosure, the vehicle 3 adopts the above-mentioned electric assembly 2 and can be adapted to different charging voltages, and has advantages such as high versatility and convenient charging.

[0124] Other configurations and operations of the integrated motor controller 1 , the electric assembly 2 , and the vehicle 3 according to the embodiment of the present disclosure are well known to those skilled in the art and will not be described in detail here.

[0125] Throughout this specification, reference to terms such as "one embodiment," "some embodiments," "illustrative embodiments," "examples," "specific examples," or "some examples" means that the specific features, structures, materials, or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present disclosure. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0126] Although the embodiments of the present disclosure have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and alterations may be made to the embodiments without departing from the principles and spirit of the present disclosure, the scope of which is defined by the claims and their equivalents.

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