A terminal block module for a motor controller

Abstract

The present invention discloses a terminal block module for a motor controller, comprising a plastic housing, a motor three-phase current detection circuit, a battery copper busbar, and a motor three-phase copper busbar. The motor three-phase copper busbar comprises three motor current guide bars, which are arranged laterally and separately, and whose lower portions are respectively embedded in the housing. The motor three-phase current detection circuit comprises a current detection circuit board, three current detection modules, and a detection signal output interface. The three current detection modules are respectively arranged on the periphery of the middle portions of the corresponding three motor current guide bars, and the three current detection modules and the detection signal output interfaces are respectively electrically connected to the current detection circuit board. The present invention can save space in the motor controller, simplify the assembly process of the motor controller, and improve the assembly efficiency of the motor controller.

Description

Technical Field

[0001] The present invention relates to a motor controller, in particular to a terminal block module of the motor controller. Background Art

[0002] The existing motor controller has a set of power input terminals and a set of power output terminals for connecting cables to the power distribution of the entire vehicle. To meet the performance requirements of electromagnetic compatibility, there will be components such as magnetic rings and safety capacitors near the terminals. At present, the structures of these input terminals and output terminals mainly include separate and semi-separate types. The separate type means that the terminal block, copper busbar conductor, input magnetic ring, output magnetic ring, safety capacitor and other components are independent and assembled together through mechanical connection; the semi-separate type means that the input copper busbar conductor is integrated with the input terminal block, the output copper busbar conductor is integrated with the output terminal block, and other components are independent.

[0003] Both the separate structure and the semi-separate structure have their shortcomings. The disadvantage of the separate structure is that the controller has many parts, the assembly on the assembly line is complicated and difficult, and the copper busbar conductors generate too much heat when current passes through them. Additional insulating thermal conductive materials are required to dissipate the heat for the copper busbar conductors, resulting in increased production costs. Although the semi-separate structure is an improvement over the separate structure, it still has the disadvantages of the separate structure.

[0004] The utility model with patent number CN201822029709.0 discloses a terminal block module, including a terminal block body, a metal conductor for conducting electricity, and an anti-interference component for resisting interference, wherein the metal conductor is integrally formed with the terminal block body, and the anti-interference component is integrally formed with the terminal block body. The utility model integrally forms the copper busbar conductor with the terminal block body through an injection molding process, and sets the magnetic ring and safety capacitor on the terminal block body by potting and other methods, so that these scattered components and the terminal block body are combined into a complete terminal block module. When participating in the assembly of the motor controller, it can reduce the assembly difficulty, improve the assembly efficiency, and facilitate the realization of automated production. At the same time, the potting of the magnetic ring can eliminate the use of the magnetic ring housing, saving costs; the terminal block module can be applied to the motor controller, and the manufactured motor controller is used to assemble the motor, and the motor is applied to new energy vehicles. However, traditional motor controllers use independent current detection circuits, require additional space, and have a cumbersome assembly process. This utility model does not take this problem into consideration. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a terminal block module of a motor controller which can save space of the motor controller and improve assembly efficiency.

[0006] In order to solve the above technical problems, the technical solution adopted by the present invention is: a terminal block module of a motor controller, comprising a plastic shell, a battery copper bus, a Y capacitor assembly and a motor three-phase copper bus, the motor three-phase copper bus comprising three motor guide bars, the three motor guide bars are arranged horizontally and separately, and the lower parts are respectively embedded in the shell; comprising a motor three-phase current detection circuit, the motor three-phase current detection circuit comprises a current detection circuit board, three current detection modules and a detection signal output interface; the three current detection modules are respectively arranged on the periphery of the middle part of the corresponding three motor guide bars, and the three current detection modules and the detection signal output interface are respectively electrically connected to the current detection circuit board; the Y capacitor assembly comprises a Y capacitor circuit board, two Y capacitors, two groups of connectors and a grounding ring, the two Y capacitors are fixed on the Y capacitor circuit board and electrically connected to the circuit of the Y capacitor circuit board; the battery copper bus comprises two positive and negative battery guide bars, the interfaces at the upper ends of the two battery guide bars are arranged horizontally and separately, and the lower parts are respectively embedded in In the shell; the lower parts of the two battery guide bars are electrically connected to the circuits of the Y capacitor circuit board through a group of connecting parts respectively; the connecting parts include a conductive long nut and two conductive screws, and the shell includes two Y capacitor bearing holes, a grounding mounting hole and two through holes for installing the conductive long nuts; the two Y capacitors are respectively embedded in the two Y capacitor bearing holes, and the conductive long nuts are embedded in the through holes for installing the conductive long nuts; the first conductive screw passes through the connecting hole at the lower part of the battery guide bar and is connected to the first end of the conductive long nut, and the second conductive screw passes through the connecting hole of the Y capacitor circuit board and is connected to the second end of the conductive long nut, thereby realizing the fixation of the Y capacitor circuit board and the electrical connection between the battery guide bar and the Y capacitor circuit board; the grounding mounting hole is arranged between the two Y capacitor bearing holes, and is a stepped hole, including a small hole as a grounding ring bearing hole and a large hole as a grounding screw mounting hole. The grounding ring is embedded in the grounding ring bearing hole and is electrically in contact with the grounding circuit of the Y capacitor circuit board. The Y capacitor circuit board includes a grounding hole, and the inner hole of the grounding ring is coaxial with the grounding hole. The terminal block module described above includes a vertical plate on the upper part of the shell, and the current detection module includes a Hall current sensor and a U-shaped shielding cover. The Hall current sensor is arranged on the front of the current detection circuit board and is electrically connected to the circuit on the current detection circuit board; the current detection circuit board is fixed on the vertical plate, and the back of the current detection circuit board is close to the front of the middle part of the three motor guide bars, and the back of the three motor guide bars is close to the front of the vertical plate; the vertical plate and the current detection circuit board respectively include three groups of mounting holes for the shielding cover, and each group of mounting holes of the vertical plate and the current detection circuit board respectively includes two through holes; the two through holes of the mounting hole group are arranged on both sides of the middle part of the corresponding motor guide bar, the bottom plate of the U-shaped shielding cover is close to the back of the vertical plate, and the two side plates of the U-shaped shielding cover pass through the through holes of the vertical plate and the current detection circuit board mounting hole group; the Hall current sensor is arranged between the two side plates of the corresponding U-shaped shielding cover.

[0007] The terminal block module described above includes 5 cable connection cavities in the lower part of the shell. The cable connection cavity includes vertically arranged cable holes and horizontally arranged connecting screw mounting holes. The connecting screw mounting holes are stepped holes, including small holes serving as threaded holes and large holes serving as connecting screw insertion holes; the upper ends of the cable holes are connected to the connecting screw insertion holes, and the lower ends of the motor guide bar and the battery guide bar with screw holes are respectively inserted into the bottom of the corresponding cable connection cavity connecting screw insertion holes.

[0008] The terminal block module described above includes two magnetic rings, and the lower part of the shell includes two annular grooves with lower openings, and the two magnetic rings are respectively embedded in the two annular grooves; the cable holes of the three cable connection cavities related to the motor guide bar are located in the inner hole of the first magnetic ring, and the cable holes of the two cable connection cavities related to the battery guide bar are located in the inner hole of the second magnetic ring.

[0009] In the above-mentioned terminal block module, the two magnetic rings are fixed in the annular groove by potting with potting glue.

[0010] In the above-mentioned terminal block module, the outer periphery of the first battery guide bar is wrapped with insulating paper.

[0011] The terminal block module described above includes a cover-opening detection switch and a switch cable connected to the controller circuit board. The cover-opening detection switch is installed on the housing with the contacts facing outward.

[0012] The above-mentioned terminal block module, battery copper busbar and motor three-phase copper busbar are embedded in the plastic shell by injection molding, and the two Y capacitors are fixed in the Y capacitor receiving holes by potting with potting glue.

[0013] The terminal block module of the present invention integrates a motor three-phase current detection circuit, which can save space in the motor controller, simplify the assembly process of the motor controller, and improve the assembly efficiency of the motor controller. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0015] Figure 1 This is a front view of the terminal block module of the motor controller according to an embodiment of the present invention.

[0016] Figure 2 It is a bottom view of the terminal block module of the motor controller according to an embodiment of the present invention.

[0017] Figure 3 It is a rear view of the terminal block module of the motor controller according to an embodiment of the present invention.

[0018] Figure 4 yes Figure 1 AA section view in.

[0019] Figure 5 It is a left side view of the terminal block module of the motor controller according to an embodiment of the present invention.

[0020] Figure 6 yes Figure 1 BB cross-section view in.

[0021] Figure 7 yes Figure 3 CC section view in.

[0022] Figure 8 yes Figure 1 DD cross-sectional view in.

[0023] Figure 9 This is a front view of a terminal block module installed on a cable according to an embodiment of the present invention.

[0024] Figure 10 yes Figure 9 EE cross-sectional view in.

[0025] Figure 11 yes Figure 9 FF cross-sectional view in. DETAILED DESCRIPTION

[0026] The structure of the terminal block module of the motor controller of the embodiment of the present invention is as follows Figures 1 to 10 As shown, it includes a plastic shell 10, a motor three-phase current detection circuit 20, a battery copper bus 30, a motor three-phase copper bus 40, a Y capacitor assembly 50, a cover opening detection switch 01 and two magnetic rings 03.

[0027] The housing 10 is made of plastic injection molding and includes a main structure 10A and a vertical plate 11. The vertical plate 11 is located above the main structure 10A. The battery copper busbar 30 and the motor three-phase copper busbar 40 are embedded in the plastic housing 10 by injection molding.

[0028] The motor three-phase copper busbar 40 includes three motor guide bars 41 , which are arranged laterally and separately, namely W-phase guide bar 41A, V-phase guide bar 41B and U-phase guide bar 41C. The lower parts of the three motor guide bars 41 are respectively embedded in the housing 10 .

[0029] The motor three-phase current detection circuit 20 includes a current detection circuit board 21, three current detection modules 20A, and a detection signal output interface 24. The three current detection modules 20A are arranged around the center of the corresponding three motor current guide bars 41. The three current detection modules 20A and the detection signal output interface 24 are electrically connected to the current detection circuit board 21. The current detection circuit board 21 is secured to the vertical plate 11 using clips 18 (or screws).

[0030] The current detection module 20A includes a Hall current sensor 22 and a U-shaped shield 23. The Hall current sensor 22 is arranged on the front of the current detection circuit board 21 and is electrically connected to the circuits on the current detection circuit board 21. The current detection circuit board 21 is fixed to the vertical plate 11, with the back of the current detection circuit board 21 close to the front of the middle portion of the three motor guide bars 41, and the back of the three motor guide bars 41 close to the front of the vertical plate 11. The vertical plate 11 and the current detection circuit board 21 each include three groups of mounting holes for the shield. Each group of mounting holes in the vertical plate 11 includes two through holes 111, and each group of mounting holes in the current detection circuit board 21 includes two through holes 211. The two through holes 111 in the vertical plate 11 mounting hole group and the two through holes 211 in the current detection circuit board 21 mounting hole group are coaxial and arranged on both sides of the middle portion of the corresponding motor guide bar 41. The bottom plate 231 of the U-shaped shield 23 rests against the back of the upright 11. Its two side plates 232 extend through the two through-holes 111 of the upright 11 mounting hole group and the two through-holes 211 of the current sensing circuit board 21 mounting hole group. The Hall effect current sensor 22 is positioned between the two side plates 232 of the U-shaped shield 23. The U-shaped shield 23 protects the Hall effect current sensor 22 from external magnetic field interference, improving the robustness of the current sensing module 20A. The Hall effect current sensor 22 can utilize the MLX91208 programmable Hall effect current sensor.

[0031] The Y capacitor assembly 50 includes a Y capacitor circuit board 51 , two Y capacitors 52 , two sets of connectors and a grounding ring 55 . The two Y capacitors 52 are fixed on the Y capacitor circuit board 51 and are electrically connected to the circuits of the Y capacitor circuit board 51 .

[0032] The battery copper busbar 30 includes two positive and negative battery conductors 31. The positive and negative battery conductors 31A and 31B are arranged laterally and separately, with their lower portions embedded in the main structure 10A of the housing 10. The outer periphery of the positive battery conductor 31A is wrapped with insulating paper 32 to ensure safety requirements between the positive and negative battery conductors 31A and 31B.

[0033] The lower portions of the positive battery guide bar 31A and the negative battery guide bar 31B are electrically connected to the circuits of the Y capacitor circuit board 51 through a set of connectors.

[0034] Each set of connecting parts includes a conductive long nut 53 and two conductive screws 54. The housing 10 includes two Y capacitor bearing holes 12, a grounding mounting hole 13 and two through holes 14 for mounting the conductive long nuts.

[0035] The two Y capacitors 52 are respectively embedded in the two Y capacitor receiving holes 12, and the two Y capacitors 52 are fixed in the Y capacitor receiving holes 12 by potting with potting glue. The conductive long nut 53 is embedded in the through hole 14. The first conductive screw 54A passes through the connection hole at the bottom of the battery guide bar 31 and is connected to the first end of the conductive long nut 53, and the second conductive screw 54B passes through the connection hole on the Y capacitor circuit board 51 and is connected to the second end of the conductive long nut 53, thereby fixing the Y capacitor circuit board 51 and electrically connecting the battery guide bar 31 and the Y capacitor circuit board 51. The two Y capacitors 52 are embedded in the Y capacitor receiving holes 12 of the shell 10 to ensure that in a vibration environment, the Y capacitor receiving holes 12 and the body and the Y capacitor circuit board 51 vibrate synchronously, thereby avoiding excessive stress on the capacitor pins and breaking.

[0036] The grounding mounting hole 13 is located between the two Y-capacitor receiving holes 12. It is a stepped hole consisting of a small hole serving as a grounding ring receiving hole 131 and a larger hole serving as a grounding screw receiving hole 132. The grounding ring 55 is inserted into the grounding ring receiving hole 131, electrically contacting the grounding circuit of the Y-capacitor circuit board 51. A grounding hole 511 is located in the center of the Y-capacitor circuit board 51. The inner hole of the grounding ring 55 is coaxial with the grounding hole 511. A grounding screw (not shown) can be inserted through the inner hole of the grounding ring 55 and the grounding hole 511, securing both to a threaded stud on the chassis to achieve grounding.

[0037] The lower portion of the housing 10 has five cable connection cavities. Each cavity includes a vertically arranged cable hole 15 and a horizontally arranged screw mounting hole 16. The screw mounting holes 16 are stepped holes, consisting of a small hole serving as a threaded hole 162 and a large hole serving as a screw insertion hole 161. The upper ends of the cable holes 15 communicate with the screw insertion holes 161. The lower ends of the motor guide bar 41 and the battery guide bar 31, each with screw holes, are inserted into the bottom of the corresponding screw insertion holes 161 in the corresponding cable connection cavity.

[0038] Two downwardly open annular grooves 17 are located on the lower portion of the housing 10 and the main structure 10A. The two magnetic rings 03 are respectively embedded in these grooves 17 and secured therein with potting compound 031. The motor cable holes 15A for the three cable connection cavities associated with the motor guide bar 41 are located within the inner hole of the first magnetic ring 03A. The battery cable holes 15B for the two cable connection cavities associated with the battery guide bar 31 are located within the inner hole of the second magnetic ring 03B.

[0039] The three motor high-voltage cables 05 are respectively inserted into the connection screw mounting holes 16 of the cable connection cavity from the three motor cable holes 15A. The connection screws 07 connect the motor high-voltage cables 05 to the motor guide bar 41 .

[0040] The two battery high-voltage cables 06 are respectively inserted into the connection screw mounting holes 16 of the cable connection cavity from the two battery cable holes 15B. The connection screws 08 connect the battery high-voltage cables 06 to the battery guide bar 31 .

[0041] The cover-open detection switch 01 is mounted on the housing 10, with its contacts facing outward. It is connected to the controller's circuit board via a switch cable 04. This switch, in conjunction with the controller's cover, detects cover opening. It is a microswitch, normally open. When the wiring cover is installed, the microswitch button is pressed down, closing the switch. When the cover is removed, the microswitch button pops up, opening the switch. The switch cable 04 transmits the cover-open detection signal to the controller's circuit board.

[0042] The terminal block module of the motor controller of the above embodiment of the present invention has the following beneficial effects:

[0043] 1) The integrated motor three-phase current detection circuit can save space in the motor controller and simplify the assembly process of the motor controller;

[0044] 2) Parts are combined into a whole through snap fastening, potting, bonding, fastening, etc., which reduces the difficulty of assembly, improves assembly efficiency, facilitates automated production, and reduces production costs;

[0045] 3) Use insulating paper between the positive and negative copper bars of the battery to reduce the gap between the positive and negative copper bars while meeting safety regulations, thereby reducing the stray inductance of the circuit;

[0046] 4) The magnetic ring is directly potted into the terminal block, eliminating the need for a magnetic ring shell, saving material and assembly costs, and enhancing the vibration resistance of the magnetic ring;

[0047] 5) Integrated cover opening detection function.

Claims

1. A terminal block module for a motor controller, comprising a plastic housing, a battery copper busbar, and a motor three-phase copper busbar, wherein the motor three-phase copper busbar comprises three motor current guide bars, which are arranged laterally and separately, and whose lower portions are respectively embedded in the housing; characterized in that: It includes a three-phase current detection circuit for a motor and a Y capacitor assembly. The three-phase current detection circuit for a motor includes a current detection circuit board, three current detection modules and a detection signal output interface. The three current detection modules are respectively arranged on the periphery of the middle part of the corresponding three motor guide bars, and the three current detection modules and the detection signal output interface are respectively electrically connected to the current detection circuit board; the Y capacitor assembly includes a Y capacitor circuit board, two Y capacitors, two sets of connectors and a grounding ring. The two Y capacitors are fixed on the Y capacitor circuit board and are electrically connected to the circuit of the Y capacitor circuit board; the battery copper bus includes two positive and negative battery guide bars, and the lower parts of the two battery guide bars are respectively embedded in the shell; the connector includes a conductive long nut and two conductive screws, and the shell includes two Y capacitor bearing holes, a grounding installation a hole and two through holes for installing conductive long nuts; two Y capacitors are respectively embedded in the two Y capacitor bearing holes, and the conductive long nuts are embedded in the through holes for installing the conductive long nuts; a first conductive screw passes through the connecting hole at the lower part of the battery guide bar and is connected to the first end of the conductive long nut, and a second conductive screw passes through the connecting hole of the Y capacitor circuit board and is connected to the second end of the conductive long nut, thereby achieving the fixation of the Y capacitor circuit board and the electrical connection between the battery guide bar and the Y capacitor circuit board; the grounding mounting hole is arranged between the two Y capacitor bearing holes and is a stepped hole, including a small hole as a grounding ring bearing hole and a large hole as a grounding screw mounting hole; the grounding ring is embedded in the grounding ring bearing hole and is electrically in contact with the grounding circuit of the Y capacitor circuit board; the Y capacitor circuit board includes a grounding hole, and the inner hole of the grounding ring is coaxial with the grounding hole.

2. The terminal block module according to claim 1, wherein: The upper part of the shell includes a vertical plate, and the current detection module includes a Hall current sensor and a U-shaped shielding cover. The Hall current sensor is arranged on the front of the current detection circuit board and is electrically connected to the circuit on the current detection circuit board; the current detection circuit board is fixed on the vertical plate, and the back of the current detection circuit board is close to the front of the middle part of the three motor guide bars, and the back of the three motor guide bars is close to the front of the vertical plate; the vertical plate and the current detection circuit board respectively include three groups of mounting holes for the shielding cover, and each group of mounting holes of the vertical plate and the current detection circuit board respectively includes two through holes; the two through holes of the mounting hole group are arranged on both sides of the middle part of the corresponding motor guide bar, the bottom plate of the U-shaped shielding cover is close to the back of the vertical plate, and the two side plates of the U-shaped shielding cover pass through the through holes of the vertical plate and the current detection circuit board mounting hole group; the Hall current sensor is arranged between the two side plates of the corresponding U-shaped shielding cover.

3. The terminal block module according to claim 1, wherein: The lower part of the shell includes 5 cable connection cavities, which include vertically arranged cable holes and horizontally arranged connecting screw mounting holes. The connecting screw mounting holes are stepped holes, including small holes serving as threaded holes and large holes serving as connecting screw insertion holes; the upper ends of the cable holes are connected to the connecting screw insertion holes, and the lower ends of the motor guide bar and the battery guide bar with screw holes are respectively inserted into the bottom of the corresponding cable connection cavity connecting screw insertion holes.

4. The terminal block module according to claim 3, characterized in that: It includes two magnetic rings, and the lower part of the shell includes two annular grooves with lower openings, and the two magnetic rings are respectively embedded in the two annular grooves; the cable holes of the three cable connection cavities related to the motor guide bar are located in the inner hole of the first magnetic ring, and the cable holes of the two cable connection cavities related to the battery guide bar are located in the inner hole of the second magnetic ring.

5. The terminal block module according to claim 4, characterized in that: The two magnetic rings are fixed in the annular groove by potting with potting glue.

6. The terminal block module according to claim 1, characterized in that: The outer periphery of the first battery guide bar is wrapped with insulating paper.

7. The terminal block module according to claim 1, wherein: It includes a cover opening detection switch and a switch cable connected to the controller circuit board. The cover opening detection switch is installed on the shell with the contact facing outward.

8. The terminal block module according to claim 1, wherein: The battery copper busbar and the motor three-phase copper busbar are embedded into the plastic shell through injection molding, and the two Y capacitors are fixed in the Y capacitor receiving holes by potting with potting glue.

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