Integrated Motor Controller and Liquid Cooling Structure of Motor Controller

Abstract

The present invention belongs to the technical field of new energy vehicles, and relates to an integrated motor controller and a liquid cooling structure for the motor controller. It solves the technical problems such as unreasonable design in the prior art. It includes a body made of a heat-conducting material, the body has a coolant channel, and on the body there are a charger cooling area for cooling the charger, a main capacitor cooling area for cooling the main capacitor, an IGBT cooling area for cooling the IGBT, a DC-DC converter cooling area for cooling the DC-DC converter, and a VCU cooling area for cooling the VCU. The advantages are as follows: By adopting a double-layer structure of the coolant channel, the integration of the new energy vehicle control system is realized, the overall layout structure of the vehicle is made compact, the cost of connection wire harnesses and their connectors is reduced, and the reliability and safety of the control system are improved; The double-layer coolant channel structure can not only meet the heat dissipation requirements of the main components, but also adopts multiple structural forms to extend to the entire control system, realizing the overall cooling of the controller, and significantly improving the cooling effect.

Description

Technical Field

[0001] The present invention belongs to the technical field of new energy vehicles, relates to a motor controller, and in particular to an integrated motor controller and a liquid cooling structure of the motor controller. Background Art

[0002] At present, the cooling methods widely used in new energy vehicles are mainly air cooling and water cooling. For new energy vehicles adopting the air cooling method currently, the cooling system has added devices such as fans and air shrouds, resulting in an excessively large axial length of the motor. The heat dissipation of the motor controller is achieved through long heat dissipation fins and heat dissipation fans, and the overall size of the motor controller is also made correspondingly large. Generally, the heat dissipation capacity of the air cooling system is proportional to the volume, and the heat dissipation capacity of the air cooling system is limited and the efficiency is low. It is difficult to be applicable to occasions with high heat dissipation pressure and limited space. At present, for new energy vehicles adopting the water cooling method, the circulating water path generally connects the motor to the gearbox, the motor controller to the motor, while the water tank and its heat dissipation fan are placed separately in another place, such as behind the front bumper of the vehicle, and the fan blows air on the surface of the water tank to cool it. This water cooling method for new energy vehicles has the following problems: 1. The arrangement of each component is too scattered, not compact enough, occupying some unnecessary installation space; 2. The cooling efficiency is low. Due to the scattered arrangement of the water cooling system, the water path is too long, affecting the cooling efficiency; 3. The heat dissipation effect is not ideal. The coolant is sent out from the water tank, passes through components such as the motor and the motor controller, and finally returns to the water tank. The entire cooling system ultimately cools by blowing the outer surface of the water tank with a fan, and the heat dissipation capacity is limited.

[0003] The motor controller controls the motor to work according to the set direction, speed, angle, and response time through the active operation of the integrated circuit. Now, the controllers of new energy vehicles are becoming more and more integrated, and the design of the water cooling structure is crucial for the control design. An excellent cooling system can greatly improve the power density of the controller and enhance the heat dissipation capacity. However, the traditional controller only performs single control on the motor, and the water channel cooling mainly targets IGBT, which cannot meet the requirements of the integrated controller system of new energy vehicles.

[0004] In order to solve the problems existing in the prior art, people have carried out long-term explorations and proposed various solutions. For example, a Chinese patent document discloses a water-cooled drive motor controller [Application No.: 201320192078.9], which includes a power input terminal, a contactor, a capacitor, a current output terminal, a control board, and a power supply board for supplying power to the control board. The contactor, the capacitor, and the power supply board are all arranged on the mounting end face of the control board. The power input terminal is connected to the control board through the contactor and the capacitor, and the control board outputs current by connecting the current output terminal. Among them, the water-cooled drive motor controller of the present invention further includes a water-cooled heat dissipation plate and a water-cooling system for supplying circulating cooling water to the water-cooled heat dissipation plate. The water-cooled heat dissipation plate is provided with cooling water channels, and both ends of the cooling water channels are connected to the water-cooling system. The water-cooled heat dissipation plate is attached and abutted against the mounting back surface of the control board.

[0005] Although the above solution solves the problem of poor heat dissipation ability of the prior art to a certain extent, this solution still has the following problems: the motor is controlled singly, and the water channel cooling mainly targets IGBT, which cannot meet the technical problems such as the controller system integration of new energy vehicles. Summary of the Invention

[0006] The purpose of the present invention is to provide a liquid cooling structure for a motor controller with reasonable design, simple structure, high degree of integration, and strong cooling effect in view of the above problems.

[0007] To achieve the above object, the present invention adopts the following technical solutions: A liquid cooling structure for a motor controller includes a body made of a heat-conducting material. The body has a coolant channel. One end of the coolant channel is connected to a first liquid inlet / outlet provided on the body, and the other end is connected to a second liquid inlet / outlet provided on the body. The body is provided with a charger cooling area for cooling the charger, a main capacitor cooling area for cooling the main capacitor, an IGBT cooling area for cooling the IGBT, a DC-DC converter cooling area for cooling the DC-DC converter, and a VCU cooling area for cooling the VCU. The charger cooling area, the main capacitor cooling area, the IGBT cooling area, the DC-DC converter cooling area, and the VCU cooling area are distributed along the coolant channel of the body.

[0008] In the above liquid cooling structure for a motor controller, the coolant channel includes a first cooling section located on one side of the body and a second cooling section located on the other side of the body. The first cooling section and the second cooling section are interconnected through a communication structure so that the coolant channel forms a double-layer channel structure. The charger cooling area, the main capacitor cooling area, the IGBT cooling area, the DC-DC converter cooling area, and the VCU cooling area are distributed on the first cooling section and the second cooling section and are respectively located on opposite sides of the body.

[0009] In the above-mentioned liquid cooling structure of the motor controller, the first cooling section includes a first bent cooling pipe and an IGBT cooling pipe disposed on one side of the body. The second cooling section includes a second bent cooling pipe disposed on the other side of the body. One end of the second bent cooling pipe is communicated with one end of the first bent cooling pipe through a communication structure disposed in the body, and the other end of the second bent cooling pipe is communicated with one end of the IGBT cooling pipe through another communication structure disposed in the body.

[0010] In the above-mentioned liquid cooling structure of the motor controller, the charger cooling area is located on the side of the body where the first bent cooling pipe is disposed. The VCU cooling area and the DC-DC converter cooling area are located on the other side of the body where the first bent cooling pipe is disposed. The VCU cooling area and the DC-DC converter cooling area are adjacent to each other and are located on both sides of the body opposite to the charger cooling area. The main capacitor cooling area is located on the side of the body where the charger cooling area is located, and the charger cooling area is opposite to the second bent cooling pipe. The IGBT cooling area is located on the side of the body where the IGBT cooling pipe is disposed.

[0011] In the above-mentioned liquid cooling structure of the motor controller, a heat exchange structure for dissipating heat by the heat conduction structure of the IGBT is provided on the IGBT cooling pipe.

[0012] In the above-mentioned liquid cooling structure of the motor controller, the heat exchange structure includes jacks opened on the IGBT cooling pipe and communicated with the inside of the IGBT cooling pipe. The jacks are evenly distributed, and each jack can be hermetically fitted with a heat dissipation pin provided on the heat conduction structure of the IGBT in a one-to-one correspondence, so that the heat dissipation pin can directly contact the coolant inside the IGBT cooling pipe. The IGBT cooling pipe radially extends to the other side of the body, and auxiliary jacks communicated with the inside of the IGBT cooling pipe are provided on this side of the body. The auxiliary jacks are evenly distributed, and each auxiliary jack can be hermetically fitted with an auxiliary heat dissipation pin on the heat dissipation plate in a one-to-one correspondence, so that the auxiliary heat dissipation pin can directly contact the coolant inside the IGBT cooling pipe. The heat dissipation plate is fixed on the body, and the heat dissipation plate is in contact with the outer wall of the second bent cooling pipe.

[0013] In the above-mentioned liquid cooling structure of the motor controller, the first bent cooling pipe is in any one of a serpentine bend, a spiral bend, and a corrugated bend; the second bent cooling pipe is in any one of a serpentine bend, a spiral bend, and a corrugated bend.

[0014] In the above-mentioned liquid cooling structure of the motor controller, the inner diameter of the communication structure at the end where the second bent cooling pipe is connected to the IGBT cooling pipe gradually decreases from the second bent cooling pipe to the IGBT cooling pipe; the inner diameter of the communication structure at the end where the first bent cooling pipe is connected to the second bent cooling pipe gradually decreases from the first bent cooling pipe to the second bent cooling pipe.

[0015] In the integrated motor controller adopting the liquid cooling structure of the motor controller, a charger is fixed on the charger cooling area, a main capacitor is fixed on the main capacitor cooling area, an IGBT is fixed on the IGBT cooling area, a DC-DC converter is fixed on the DC-DC converter cooling area, and a VCU is fixed on the VCU cooling area.

[0016] In the above-mentioned integrated motor controller, several heat dissipation pins are provided on the heat conduction structure of the IGBT. The heat dissipation pins are in sealed cooperation with the jacks so that the heat dissipation pins can directly contact the coolant in the IGBT cooling pipe; a heat dissipation plate with several auxiliary heat dissipation pins is fixed on the body. The auxiliary jacks can be in sealed cooperation with the auxiliary heat dissipation pins on the heat dissipation plate one by one so that the auxiliary heat dissipation pins can directly contact the coolant in the IGBT cooling pipe, and the heat dissipation plate is in contact with the outer wall of the second bent cooling pipe.

[0017] Compared with the existing technology, the advantages of the present integrated motor controller and the liquid cooling structure of the motor controller are as follows: By adopting a double-layer structure of the coolant channel, the integration of the new energy vehicle control system is realized, the overall vehicle layout structure is made compact, the cost of connection wire harnesses and their connectors is reduced, and the reliability and safety of the control system are improved; The double-layer coolant channel structure can not only meet the heat dissipation requirements of the main components, but also adopt multiple structural forms to extend to the entire control system, realizing the overall cooling of the controller, and the cooling effect is significantly improved. Description of the Drawings

[0018] Figure 1 A top view schematic diagram of the liquid cooling structure of the motor controller of the present invention is provided.

[0019] Figure 2 A bottom view schematic diagram of the liquid cooling structure of the motor controller of the present invention is provided.

[0020] Figure 3 A top view schematic diagram of the integrated motor controller of the present invention is provided.

[0021] Figure 4 A bottom view schematic diagram of the integrated motor controller of the present invention is provided.

[0022] In the figure, there are body 1, coolant channel 2, first cooling section 201, first bent cooling pipe 2011, IGBT cooling pipe 2012, jack 2013, second cooling section 202, second bent cooling pipe 2021, charger 3, charger cooling area 301, main capacitor 4, main capacitor cooling area 401, IGBT cooling area 5, DC-DC converter 6, DC-DC converter cooling area 601, VCU cooling area 7, and heat dissipation plate 8. Detailed implementation mode

[0023] The present invention will be further described in detail below with reference to the accompanying drawings and specific implementation modes.

[0024] As Figure 1 and 2 shown, the liquid cooling structure of this motor controller includes a body 1 made of a heat-conducting material. The body 1 has a coolant channel 2. One end of the coolant channel 2 is connected to a first liquid inlet / outlet provided on the body 1, and the other end is connected to a second liquid inlet / outlet provided on the body 1. The body 1 is provided with a charger cooling area 301 for cooling the charger 3, a main capacitor cooling area 401 for cooling the main capacitor 4, an IGBT cooling area 5 for cooling the IGBT, a DC-DC converter cooling area 601 for cooling the DC-DC converter 6, and a VCU cooling area 7 for cooling the VCU. The charger cooling area 301, main capacitor cooling area 401, IGBT cooling area 5, DC-DC converter cooling area 601, and VCU cooling area 7 are distributed along the coolant channel 2 of the body 1.

[0025] Specifically, the coolant channel 2 includes a first cooling section 201 located on one side of the body 1 and a second cooling section 202 located on the other side of the body 1. The first cooling section 201 and the second cooling section 202 are interconnected through a communication structure so that the coolant channel 2 forms a double-layer channel structure. The charger cooling area 301, the main capacitor cooling area 401, the IGBT cooling area 5, the DC-DC converter cooling area 601, and the VCU cooling area 7 are distributed on the first cooling section 201 and the second cooling section 202 and are respectively located on the opposite sides of the body 1. Among them, the first cooling section 201 includes a first bent cooling pipe 2011 and an IGBT cooling pipe 2012 arranged on one side of the body 1, and the second cooling section 202 includes a second bent cooling pipe 2021 arranged on the other side of the body 1. One end of the second bent cooling pipe 2021 is connected to one end of the first bent cooling pipe 2011 through a communication structure provided in the body 1, and the other end of the second bent cooling pipe 2021 is connected to one end of the IGBT cooling pipe 2012 through another communication structure provided in the body 1. The first bent cooling pipe 2011 is bent in any one of a serpentine shape, a spiral shape, and a waveform shape; the second bent cooling pipe 2021 is bent in any one of a serpentine shape, a spiral shape, and a waveform shape. A heat conduction pad can be fixedly arranged on the outside of the first bent cooling pipe 2011. The inner side of the heat conduction pad has a groove that fits the first bent cooling pipe 2011, and the outside can be in contact with the charger. A number of through holes can also be provided on the heat conduction pad to facilitate heat exchange.

[0026] In this embodiment, the charger cooling area 301 is located on the side of the main body 1 where the first bent cooling pipe 2011 is provided, and the VCU cooling area 7 and the DC-DC converter cooling area 601 are located on the other side of the main body 1 where the first bent cooling pipe 2011 is provided. The VCU cooling area 7 and the DC-DC converter cooling area 601 are adjacent to each other and are located on two sides of the main body 1 opposite to the charger cooling area 301. The main capacitor cooling area 401 is located on the side of the main body 1 where the charger cooling area 301 is located, and the charger cooling area 301 is opposite to the second bent cooling pipe 2021. The IGBT cooling area 5 is located on the side of the main body 1 where the IGBT cooling pipe 2012 is provided. A heat exchange structure for dissipating heat by the heat conduction structure of the IGBT is provided on the IGBT cooling pipe 2012. Preferably, the heat exchange structure includes sockets 2013 opened on the IGBT cooling pipe 2012 and communicating with the inside of the IGBT cooling pipe 2012. The sockets 2013 are evenly distributed, and each socket 2013 can be hermetically fitted with a heat dissipation pin provided on the heat conduction structure of the IGBT in a one-to-one correspondence, so that the heat dissipation pin can directly contact the coolant in the IGBT cooling pipe 2012. The IGBT cooling pipe 2012 extends radially to the other side of the main body 1, and auxiliary sockets 2013 communicating with the inside of the IGBT cooling pipe 2012 are provided on this side of the main body 1. The auxiliary sockets 2013 are evenly distributed, and each auxiliary socket 2013 can be hermetically fitted with an auxiliary heat dissipation pin on the heat dissipation plate 8 in a one-to-one correspondence, so that the auxiliary heat dissipation pin can directly contact the coolant in the IGBT cooling pipe 2012. The heat dissipation plate 8 is fixed on the main body 1, and the heat dissipation plate 8 is in contact with the outer wall of the second bent cooling pipe 2021.

[0027] The inner diameter of the communication structure at the connected end of the second bent cooling pipe 2021 and the IGBT cooling pipe 2012 gradually decreases from the second bent cooling pipe 2021 to the IGBT cooling pipe 2012; the inner diameter of the communication structure at the connected end of the first bent cooling pipe 2011 and the second bent cooling pipe 2021 gradually decreases from the first bent cooling pipe 2011 to the second bent cooling pipe 2021.

[0028] As Figure 3 and 4As shown in the figure, an integrated motor controller adopting the above-mentioned liquid cooling structure of the motor controller has a charger 3 fixed on the charger cooling area 301, a main capacitor 4 fixed on the main capacitor cooling area 401, an IGBT fixed on the IGBT cooling area 5, a DC-DC converter 6 fixed on the DC-DC converter cooling area 601, and a VCU fixed on the VCU cooling area 7. The heat conduction structure of the IGBT is provided with a plurality of heat dissipation pins, and the heat dissipation pins are hermetically fitted with the jacks 2013 so that the heat dissipation pins can directly contact the coolant in the IGBT cooling pipe 2012; a heat dissipation plate 8 with a plurality of auxiliary heat dissipation pins is fixed on the body 1, and the auxiliary jacks 2013 can be hermetically fitted with the auxiliary heat dissipation pins on the heat dissipation plate 8 one by one so that the auxiliary heat dissipation pins can directly contact the coolant in the IGBT cooling pipe 2012, and the heat dissipation plate 8 contacts the outer wall of the second bent cooling pipe 2021.

[0029] The present invention realizes the integration of the motor controller, integrating the IGBT, the main capacitor, the charger, the DC-DC converter and the VCU. The coolant channel 2 widely covers the entire body 1, greatly improving the power density of the motor controller, enhancing the heat dissipation capacity and reducing the temperature rise; at the same time, it realizes the integration of the new energy electric vehicle control system. In addition, a double-layer structure of the coolant channel 2 is adopted to form a drop, further realizing the compactness of the integrated layout of the motor controller; the coolant channel 2 of the present invention adopts a local structure optimization design. For the parts of the components with low power consumption, the coolant channel 2 is simplified so that it can not only meet the heat dissipation performance but also reduce the water pressure loss.

[0030] In this embodiment, criss-cross heat dissipation ribs are designed in the VCU cooling area 7 to further improve the heat exchange efficiency. Mounting lugs are provided on the side of the body 1 for convenient fixed installation. The second bent cooling pipe 2021 is in a U shape; while the first bent cooling pipe 2011 is in a serpentine bend. The first bent cooling pipe 2011 here can also be designed into a spiral disc shape.

[0031] The specific embodiments described herein are merely illustrative of the spirit of the present invention. Those skilled in the art of the present invention can make various modifications or supplements to the described specific embodiments or use similar ways to replace them, but will not deviate from the spirit of the present invention or exceed the scope defined by the appended claims.

[0032] Although terms such as ontology 1, coolant channel 2, first cooling section 201, first bent cooling pipe 2011, IGBT cooling pipe 2012, jack 2013, second cooling section 202, second bent cooling pipe 2021, charger 3, charger cooling area 301, main capacitor 4, main capacitor cooling area 401, IGBT cooling area 5, DC-DC converter 6, DC-DC converter cooling area 601, VCU cooling area 7, heat dissipation plate 8 are used more frequently in this text, the possibility of using other terms is not excluded. The use of these terms is only for more convenient description and explanation of the essence of the present invention; interpreting them as any additional limitation is contrary to the spirit of the present invention.

Claims

1. A liquid cooling structure for a motor controller, comprising a body (1) made of a heat-conducting material. The body (1) has a coolant channel (2). One end of the coolant channel (2) is connected to a first liquid inlet / outlet provided on the body (1), and the other end is connected to a second liquid inlet / outlet provided on the body (1). It is characterized in that, The described body (1) is provided with a charger cooling area (301) for cooling the charger (3), a main capacitor cooling area (401) for cooling the main capacitor (4), an IGBT cooling area (5) for cooling the IGBT, a DC-DC converter cooling area (601) for cooling the DC-DC converter (6), and a VCU cooling area (7) for cooling the VCU; The described coolant channel (2) includes a first cooling section (201) on one side of the body (1) and a second cooling section (202) on the other side of the body (1). The first cooling section (201) and the second cooling section (202) are interconnected through a connecting structure, so that the coolant channel (2) forms a double-layer channel structure. The charger cooling area (301), the main capacitor cooling area (401), the IGBT cooling area (5), the DC-DC converter cooling area (601), and the VCU cooling area (7) are distributed on the first cooling section (201) and the second cooling section (202). And the VCU cooling area (7), the DC-DC converter cooling area (601) and the main capacitor cooling area (401), the charger cooling area (301) are located on two sides of the body (1) oppositely.

2. The liquid cooling structure of the motor controller according to claim 1, wherein The described first cooling section (201) includes a first bent cooling pipe (2011) and an IGBT cooling pipe (2012) arranged on one side of the body (1). The second cooling section (202) includes a second bent cooling pipe (2021) arranged on the other side of the body (1). One end of the second bent cooling pipe (2021) is connected to one end of the first bent cooling pipe (2011) through a connecting structure arranged in the body (1). The other end of the second bent cooling pipe (2021) is connected to one end of the IGBT cooling pipe (2012) through another connecting structure arranged in the body (1).

3. The liquid cooling structure of the motor controller according to claim 2, wherein, The described charger cooling area (301) is located on the side of the body (1) where the first bent cooling pipe (2011) is arranged. The VCU cooling area (7) and the DC-DC converter cooling area (601) are located on the other side of the body (1) where the first bent cooling pipe (2011) is arranged. The VCU cooling area (7) and the DC-DC converter cooling area (601) are arranged adjacent to each other; the charger cooling area (301) is opposite to the second bent cooling pipe (2021); the IGBT cooling area (5) is located on the side of the body (1) where the IGBT cooling pipe (2012) is arranged.

4. The liquid cooling structure of the motor controller according to claim 2 or 3, characterized in that, The described IGBT cooling pipe (2012) is provided with a heat exchange structure for dissipating heat through the heat conduction structure of the IGBT.

5. The liquid cooling structure of the motor controller according to claim 4, characterized in that, The heat exchange structure described above includes jacks (2013) opened on the IGBT cooling pipe (2012) and communicating with the inside of the IGBT cooling pipe (2012). The jacks (2013) are evenly distributed, and each jack (2013) can be hermetically fitted with the heat dissipation pins provided on the heat conduction structure of the IGBT in a one-to-one correspondence, so that the heat dissipation pins can directly contact the coolant in the IGBT cooling pipe (2012); the IGBT cooling pipe (2012) extends radially to the other side of the body (1), and auxiliary jacks communicating with the inside of the IGBT cooling pipe (2012) are provided on this side of the body (1). The auxiliary jacks are evenly distributed, and each auxiliary jack can be hermetically fitted with the auxiliary heat dissipation pins on the heat dissipation plate (8) in a one-to-one correspondence, so that the auxiliary heat dissipation pins can directly contact the coolant in the IGBT cooling pipe (2012). The heat dissipation plate (8) is fixed on the body (1), and the heat dissipation plate (8) contacts the outer wall of the second bent cooling pipe (2021).

6. The liquid cooling structure of the motor controller according to claim 2 or 3, characterized in that The first bent cooling pipe (2011) is bent in any one of a serpentine shape, a spiral shape, and a waveform shape; the second bent cooling pipe (2021) is bent in any one of a serpentine shape, a spiral shape, and a waveform shape.

7. The liquid cooling structure of the motor controller according to claim 2 or 3, characterized in that, The inner diameter of the communication structure at the end where the second bent cooling pipe (2021) is connected to the IGBT cooling pipe (2012) gradually decreases from the second bent cooling pipe (2021) to the IGBT cooling pipe (2012); the inner diameter of the communication structure at the end where the first bent cooling pipe (2011) is connected to the second bent cooling pipe (2021) gradually decreases from the first bent cooling pipe (2011) to the second bent cooling pipe (2021).

8. The liquid cooling structure of the motor controller according to claim 5, characterized in that A number of heat dissipation pins are provided on the heat conduction structure of the IGBT. The heat dissipation pins are hermetically fitted with the jacks (2013) so that the heat dissipation pins can directly contact the coolant in the IGBT cooling pipe (2012); a heat dissipation plate (8) with a number of auxiliary heat dissipation pins is fixed on the body (1). The auxiliary jacks can be hermetically fitted with the auxiliary heat dissipation pins on the heat dissipation plate (8) in a one-to-one correspondence, so that the auxiliary heat dissipation pins can directly contact the coolant in the IGBT cooling pipe (2012). The heat dissipation plate (8) contacts the outer wall of the second bent cooling pipe (2021).

9. An integrated motor controller adopting the liquid cooling structure of the motor controller according to any one of claims 1-7, characterized in that A charger (3) is fixed on the charger cooling area (301), a main capacitor (4) is fixed on the main capacitor cooling area (401), an IGBT is fixed on the IGBT cooling area (5), a DC-DC converter (6) is fixed on the DC-DC converter cooling area (601), and a VCU is fixed on the VCU cooling area (7).

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