A high power density motor controller for electric vehicles

Abstract

The application relates to a high-power-density motor controller for an electric vehicle, comprising a box body provided with an opening, wherein the opening of the box body is provided with a box cover, and the box body is provided with a power module, a film capacitor, a magnetic ring assembly, a current sensor assembly, a heat dissipation device and a driving control board; the surface of the power module is provided with heat dissipation fins, the bottom of the box body is provided with a water tank, the top of the water tank is provided with a sealing cover plate, the water tank is provided with cooling liquid, the power module is arranged in the cooling liquid of the water tank, and the terminal of the power module extends from the sealing cover plate. Compared with the prior art, the high-power-density power module is directly arranged in the water tank, can directly exchange heat with the cooling liquid, has good heat dissipation effect, improves the output capacity of the motor controller under the condition of peak power, improves the power density of the whole motor controller, and has the advantages of small size, light weight and convenient automatic assembly.

Description

TECHNICAL FIELD

[0001] The present application relates to a motor controller, in particular to a high power density motor controller for electric vehicles. BACKGROUND

[0002] With the continuous development of electric vehicle technology, electric vehicles are increasingly popular in people's daily life, and the motor controller is a core component inside the electric vehicle, and its safe and reliable operation is the key to the normal operation of the entire electric vehicle. The core power module in the traditional motor controller is usually controlled by a conventional IGBT, but the conventional IGBT is usually cooled by increasing a heat sink or a heat sink plate. The heat sink and the heat sink plate increase the thermal resistance of the cooling process, resulting in poor IGBT cooling effect. The limitations of this cooling method also seriously limit the improvement of the power density of the motor controller itself. Therefore, if the power density of the motor controller is to be improved, the volume of the motor controller must be increased, but this is difficult to meet the requirements of the internal space layout and power density of the entire vehicle, and also limits the improvement of the power of the electric vehicle. Therefore, there is an urgent need to design a high power density motor controller with good cooling performance, high power density, small size, light weight and suitable for mass assembly to meet the development needs of the domestic new energy vehicle industry. SUMMARY

[0003] The purpose of the present application is to overcome the defects of the prior art and provide a high power density motor controller for electric vehicles.

[0004] The purpose of the present application can be achieved by the following technical solutions:

[0005] A high power density motor controller for electric vehicles, comprising a box body provided with an opening, the opening of the box body is provided with a box cover, the box body is provided with a power module, a film capacitor, a magnetic ring assembly, a current sensor assembly, a heat dissipation device and a drive control board; the surface of the power module is provided with a heat dissipation fin, the bottom of the box body is provided with a water tank, the top of the water tank is provided with a sealing cover plate, the water tank is provided with cooling liquid, the power module is arranged in the cooling liquid of the water tank, and the terminal of the power module extends from the sealing cover plate.

[0006] Preferably, the box body is provided with a first water inlet and a first water outlet, the bottom of the water tank is provided with a second water inlet and a second water outlet respectively communicating with the first water inlet and the first water outlet, the second water inlet and the second water outlet are respectively arranged at two ends of the water tank, and the height of the second water outlet is higher than that of the second water inlet.

[0007] Preferably, the water tank comprises a plurality of water tank cavities arranged side by side and communicating with each other, and each of the water tank cavities is provided with a power module.

[0008] Preferably, the outer side wall of the box is provided with a three-phase output plug-in unit, a busbar input plug-in unit and an interface board.

[0009] Preferably, the current sensor assembly comprises a support and a current sensor, a three-phase output pole plate and a three-phase switching output pole plate arranged on the support; the input end of the three-phase switching output pole plate is electrically connected with the output end of the power module; the output end of the three-phase switching output pole plate is fixed on the support together with the input end of the three-phase output pole plate through the current sensor and realizes electrical connection; the output end of the three-phase output pole plate is electrically connected with the three-phase output plug-in unit.

[0010] Preferably, the support is provided with a support column and a slot, the slot is in the shape of an L-shaped bend, the three-phase output pole plate is inserted into the slot, and the input end and the output end thereof are respectively directed to two perpendicular directions.

[0011] Preferably, the input end of the thin film capacitor is electrically connected with the busbar input plug-in unit after passing through the hole in the middle of the magnetic ring assembly, and the output end of the thin film capacitor is electrically connected with the input end of the power module.

[0012] Preferably, the input end of the thin film capacitor comprises a positive input pole plate and a negative input pole plate, and the output end thereof comprises a positive output pole plate and a negative output pole plate, and the positive input pole plate and the negative input pole plate and the positive output pole plate and the negative output pole plate are arranged in an insulating laminated manner.

[0013] Preferably, the positive output pole plate and the negative output pole plate horizontally extend and have different lengths, and the ends of the positive output pole plate and the negative output pole plate are respectively provided with a vertically arranged connecting part.

[0014] Preferably, the current sensor assembly and the thin film capacitor are respectively arranged on the two sides of the water tank along the arrangement direction of the terminals of the power module, the drive control board is arranged above the power module and is electrically connected with the signal terminals of the power module.

[0015] Compared with the prior art, the present application has the following advantages:

[0016] 1. The power module with smaller volume can directly exchange heat with the cooling liquid, the water tank is arranged on the motor controller box, the power module is tightly attached to the heat dissipation fins on two sides, and then is inserted into the water tank, the heat dissipation fins can ensure that the water flow in the water tank is uniform, so that the power module in the water tank can directly and uniformly exchange heat with the cooling liquid, the cooling liquid can quickly take away the heat generated by the power module, the good heat dissipation effect is achieved, the stable output capacity of the motor controller under the peak working condition is ensured, the current use capacity of the power module itself can be improved, the motor controller can output higher peak power, and the power density of the entire motor controller is improved, and the volume and weight of the motor controller are reduced.

[0017] 2. The entire motor controller directly selects the water tank for heat dissipation, the special heat dissipation device and the heat dissipation plate for dissipating heat of the power module are avoided, assembly space is saved, the volume of the entire device is reduced, the integration of the entire controller is improved, and the cost of the motor controller is saved.

[0018] 3. The entire motor controller can be assembled in a modular manner, the assembly of the heat dissipation device and the current sensor assembly can be completed offline, and each block structure is formed, finally, the current sensor assembly, the film capacitor, the driving control board, the box cover, the three-phase output plug-in, the bus input plug-in, the magnetic ring assembly and the interface board are assembled, and a highly integrated modular structure is formed, so that the assembly is convenient, the automation production is suitable, and the integration of the entire motor controller can be improved. BRIEF DESCRIPTION OF DRAWINGS

[0019] Figure 1 It is an exploded view of the motor controller of the application;

[0020] Figure 2 It is an exploded view of the heat dissipation device of the motor controller of the application;

[0021] Figure 3 It is a box structure schematic view of the motor controller of the application;

[0022] Figure 4 It is a sealing cover plate structure schematic view of the motor controller of the application;

[0023] Figure 5 It is a current sensor assembly structure schematic view of the motor controller of the application;

[0024] Figure 6 It is a support structure schematic view of the motor controller of the application;

[0025] Figure 7 It is a film capacitor structure schematic view of the motor controller of the application;

[0026] Figure 8A cooling liquid flow schematic diagram of the motor controller of the present application.

[0027] Fig. annotations: 1, heat dissipation device, 2, film capacitor, 3, drive control board, 4, box cover, 5, current sensor assembly, 6, three-phase output plug-in, 7, bus input plug-in, 8, magnetic ring assembly, 9, interface board, 1-1, box, 1-2, water inlet pipe, 1-3, power module, 1-4, heat dissipation fin, 1-5, water outlet pipe, 1-6, sealing cover plate, 2-1, positive input plate, 2-2, negative input plate, 2-3, positive output plate, 2-4, negative output plate, 2-5, shell, 5-1, three-phase switching output plate, 5-2, current sensor, 5-3, three-phase output plate, 5-4, support, 1-1-1, first water inlet, 1-1-2, second water inlet, 1-1-3, water tank, 1-1-4, second water outlet, 1-1-5, first water outlet. DETAILED DESCRIPTION

[0028] The present application will be described in detail below with reference to the accompanying drawings and specific embodiments. The present embodiment is implemented on the basis of the technical scheme of the present application, and gives a detailed implementation and specific operation process, but the protection scope of the present application is not limited to the following examples.

[0029] EMBODIMENT

[0030] For the defects that the motor controller power module cannot directly exchange heat with the cooling liquid and the power density is low, if an IGBT that can be directly inserted into the cooling liquid for cooling can be developed, the IGBT can be directly cooled without designing a heat sink or a heat dissipation plate, and the IGBT can directly exchange heat with the cooling liquid in the cooling liquid, so that the power density of the motor controller can be greatly improved without increasing the volume of the motor controller, which has a great competitive advantage in the whole vehicle layout space.

[0031] As shown in Figure 1 The present application provides a high-power-density motor controller for electric vehicles, which comprises a box 1-1 provided with an opening, the opening of the box 1-1 is provided with a box cover 4, and the box 1-1 is provided with a power module 1-3, a film capacitor 2, a magnetic ring assembly 8, a current sensor assembly 5, a heat dissipation device 1 and a drive control board 3. The film capacitor 2, the magnetic ring assembly 8 and the current sensor assembly 5 are fixed on the bottom surface of the box 1-1. The box cover 4 is fixed above the box 1-1 to realize the sealing of the whole motor controller.

[0032] As shown in Figure 2As shown in the figure, the bottom of the box 1-1 is provided with a water tank 1-1-3, the top of the water tank 1-1-3 is provided with a sealing cover plate 1-6, the water tank 1-1-3 is provided with cooling liquid, the surface of the power module 1-3 is tightly attached to the heat dissipation fins 1-4 and then inserted into the water tank 1-1-3, and the terminals of the power module 1-3 extend from the sealing cover plate 1-6. The water tank 1-1-3 includes multiple water tank cavities arranged side by side and connected to each other, and each water tank cavity is provided with a power module 1-3.

[0033] As shown in the figure, Figure 3 The box 1-1 is provided with a first water inlet 1-1-1 and a first water outlet 1-1-5, and the bottom of the water tank 1-1-3 is provided with a second water inlet 1-1-2 and a second water outlet 1-1-4 which are respectively connected to the first water inlet 1-1-1 and the first water outlet 1-1-5. The second water inlet 1-1-2 and the second water outlet 1-1-4 are respectively arranged at the two ends of the water tank 1-1-3, the second water inlet 1-1-2 is located at the bottom surface of the water tank 1-1-3, the second water outlet 1-1-4 is located at the highest surface of the water tank 1-1-3, and there is a height difference between the two. The outer side of the box 1-1 is respectively provided with a water inlet pipe 1-2 and a water outlet pipe 1-5 which are respectively connected to the first water inlet 1-1-1 and the first water outlet 1-1-5 and are fixed on the box 1-1 by cold pressing.

[0034] The surface of the opening of the water tank 1-1-3 is provided with sealing grooves which are connected to each other. As shown in the figure, Figure 4 The sealing cover plate 1-6 has three rectangular holes arranged side by side for the terminals of the power module 1-3 to extend out, and each of the three rectangular holes is surrounded by a sealing groove. The sealing grooves are respectively provided with sealing rings.

[0035] The outer side wall of the box 1-1 is provided with a three-phase output plug-in 6, a bus input plug-in 7 and an interface board 9.

[0036] As shown in the figure, Figure 5 The current sensor assembly 5 includes a support 5-4, a current sensor 5-2, a three-phase output plate 5-3 and a three-phase switching output plate 5-1 arranged on the support 5-4, and the support 5-4 is fixed on the bottom surface of the box 1-1. The input end of the three-phase switching output plate 5-1 is electrically connected to the output end of the power module 1-3 by laser welding, the output end of the three-phase switching output plate 5-1 penetrates through the current sensor 5-2 and is electrically connected to the input end of the three-phase output plate 5-3 by bolts and is fixed on the support 5-4. The output end of the three-phase output plate 5-3 is electrically connected to the terminals of the three-phase output plug-in 6. As shown in the figure, Figure 6 The support 5-4 is provided with a support column and a slot, in this embodiment, the slot is L-shaped and has three bends, the three-phase output plate 5-3 is inserted into the three slots to achieve electrical clearance isolation, and the input end and the output end of the three-phase output plate 5-3 are respectively directed to two perpendicular directions.

[0037] As shown in Figure 7 The thin film capacitor 2 includes a shell 2-5, and the shell 2-5 is provided with an input end and an output end. The input end of the thin film capacitor 2 includes a positive input plate 2-1 and a negative input plate 2-2, and the input end of the thin film capacitor 2 is electrically connected with the busbar input plug 7 after passing through the hole in the middle of the magnetic ring assembly 8. The output end of the thin film capacitor 2 includes a positive output plate 2-3 and a negative output plate 2-4, and the output end of the thin film capacitor 2 is electrically connected with the input end of the power module 1-3. The positive input plate 2-1 and the negative input plate 2-2, and the positive output plate 2-3 and the negative output plate 2-4 are arranged in an insulating laminated manner, which can reduce inductance and help the power module 1-3 dissipate heat. The positive output plate 2-3 and the negative output plate 2-4 horizontally extend from the shell 2-5 and have different lengths, and the ends of the positive output plate 2-3 and the negative output plate 2-4 are respectively provided with a vertically arranged rectangular connecting part, which is electrically connected with the positive input end and the negative input end of the power module 1-3 through laser welding.

[0038] In this embodiment, the current sensor assembly 5 and the thin film capacitor 2 are respectively arranged on both sides of the water tank 1-1-3 along the terminal arrangement direction of the power module 1-3. The drive control board 3 is arranged above the power module 1-3, one side of the drive control board 3 is fixed on the support column of the support 5-4, the other side is fixed on the fixing hole of the thin film capacitor 2, and the signal terminal of the power module 1-3 is electrically connected with the drive control board 3 through tin soldering.

[0039] The assembly process of the motor controller is as follows:

[0040] (1) First, install the heat dissipation device 1: insert the inlet pipe 1-2 and the outlet pipe 1-5 into the second water inlet 1-1-2 and the second water outlet 1-1-4 on the box body 1-1 through cold pressing, then paste the heat dissipation fins 1-4 on the positive and negative surfaces of the power module 1-3, then insert the power module 1-3 with the heat dissipation fins 1-4 into the water tank 1-1-3 on the bottom surface of the box body 1-1, then install the sealing ring in the sealing groove on the water tank 1-1-3 and the sealing groove on the sealing cover plate 1-6, and finally fix the sealing cover plate 1-6 with the sealing ring on the water tank 1-1-3, thus completing the installation of the heat dissipation device 1.

[0041] (2) Then, assemble the current sensor assembly 5: first, assemble the current sensor 5-2 on the support 5-4, then place the three-phase output plate 5-3 in the L-shaped slot of the support 5-4, and then fix the three-phase switching output plate 5-1 on the support 5-4 together with the three-phase output plate 5-3 through the current sensor 5-2, thus completing the assembly of the current sensor assembly 5.

[0042] (3) The magnetic ring assembly 8 is sleeved on the input end of the film capacitor 2, and then the current sensor assembly 5 is assembled on the bottom surface of the box body 1-1, respectively, then the output end of the film capacitor 2 is laser welded with the input end of the power module 1-3, and the input end of the three-phase switching output plate 5-1 of the current sensor assembly 5 is laser welded with the output end of the power module 1-3, respectively; then the three-phase output plug-in 6, the bus input plug-in 7, and the interface plate 9 are fixed on the side wall of the box body 1-1, the terminal of the three-phase output plug-in 6 is connected and fixed with the output end of the three-phase output plate 5-3 of the current sensor assembly 5, and the terminal of the bus input plug-in 7 is connected and fixed with the input end of the film capacitor 2; then the drive control plate 3 is fixed above the support 5-4 and the film capacitor 2, respectively, and the drive control plate 3 is soldered with the signal terminal of the power module 1-3 by tin soldering.

[0043] (4) Finally, the box cover 4 is fixed above the box body 1-1, and the assembly of the high-power density motor controller is completed.

[0044] As shown in Figure 8 , the overall trajectory of the cooling liquid flowing in the water channel during the operation of the controller is as follows: first, the cooling liquid enters the second water inlet 1-1-2 of the controller box body 1-1 from the water inlet pipe 1-2, then enters the inside of the water tank 1-1-3 from the first water inlet 1-1-1, because the bottom of the water tank 1-1-3 is connected to the first water inlet 1-1-1, and the upper part is connected to the first water outlet 1-1-5, there is a height difference between the first water inlet 1-1-1 and the first water outlet 1-1-5, which can ensure the water storage function of the water tank 1-1-3, when the water storage level in the water tank 1-1-3 reaches the position of the first water outlet 1-1-5 at the upper end, the cooling liquid will flow out from the first water outlet 1-1-5 into the second water outlet 1-1-4, and finally flow out from the water outlet pipe 1-5, completing the heat dissipation cycle inside the controller and ensuring the uniform and normal heat dissipation of the entire power module 1-3.

Claims

1. A high-power-density motor controller for electric vehicles, comprising a box (1-1) provided with an opening, the opening of the box (1-1) being provided with a box cover (4), the box (1-1) being provided with a power module (1-3), a film capacitor (2), a magnetic ring assembly (8), a current sensor assembly (5), a heat dissipation device (1) and a drive control board (3); characterized in that, The surface of the power module (1-3) is provided with a heat dissipation fin (1-4), the bottom of the box (1-1) is provided with a water tank (1-1-3), the top of the water tank (1-1-3) is provided with a sealing cover plate (1-6), the water tank (1-1-3) is provided with cooling liquid, the power module (1-3) is arranged in the cooling liquid in the water tank (1-1-3), and the terminal of the power module (1-3) extends from the sealing cover plate (1-6). The heat dissipation fin (1-4) makes the water in the water tank (1-1-3) flow uniformly, and the power module (1-3) directly exchanges heat with the cooling liquid in the water tank (1-1-3). The box (1-1) is provided with a first water inlet (1-1-1) and a first water outlet (1-1-5), the bottom of the water tank (1-1-3) is provided with a second water inlet (1-1-2) and a second water outlet (1-1-4) which are communicated with the first water inlet (1-1-1) and the first water outlet (1-1-5) respectively, the second water inlet (1-1-2) and the second water outlet (1-1-4) are arranged at two ends of the water tank (1-1-3) respectively, and the height of the second water outlet (1-1-4) is higher than that of the second water inlet (1-1-2). The water tank (1-1-3) comprises a plurality of water tank cavities arranged side by side and communicated with each other, and each of the water tank cavities is provided with a power module (1-3).

2. A high power density motor controller for an electric vehicle according to claim 1, wherein, The outer side wall of the box (1-1) is provided with a three-phase output plug-in component (6), a bus input plug-in component (7) and an interface plate (9).

3. A high power density motor controller for an electric vehicle according to claim 2, wherein, The current sensor assembly (5) comprises a support (5-4) and a current sensor (5-2), a three-phase output pole plate (5-3) and a three-phase switching output pole plate (5-1) arranged on the support (5-4); the input end of the three-phase switching output pole plate (5-1) is electrically connected with the output end of the power module (1-3), the output end of the three-phase switching output pole plate (5-1) penetrates the current sensor (5-2) and is fixed on the support (5-4) together with the input end of the three-phase output pole plate (5-3) and realizes electrical connection; the output end of the three-phase output pole plate (5-3) is electrically connected with the three-phase output plug-in component (6).

4. A high power density motor controller for an electric vehicle according to claim 3, wherein, The support (5-4) is provided with a support column and a slot, the slot is in the shape of L-shaped bending, the three-phase output pole plate (5-3) is inserted into the slot, and the input end and the output end thereof are respectively directed to two perpendicular directions.

5. A high power density motor controller for electric vehicles as claimed in claim 2, wherein, The input end of the thin film capacitor (2) is electrically connected with the bus input plug-in component (7) after penetrating the hole in the middle of the magnetic ring assembly (8), and the output end of the thin film capacitor (2) is electrically connected with the input end of the power module (1-3).

6. A high power density motor controller for an electric vehicle according to claim 5, wherein, The input end of the thin film capacitor (2) comprises a positive input pole plate (2-1) and a negative input pole plate (2-2), the output end thereof comprises a positive output pole plate (2-3) and a negative output pole plate (2-4), and the positive input pole plate (2-1) and the negative input pole plate (2-2) and the positive output pole plate (2-3) and the negative output pole plate (2-4) are arranged in an insulating laminated manner.

7. A high power density motor controller for an electric vehicle according to claim 6, wherein, The positive output plate (2-3) and the negative output plate (2-4) horizontally extend and have different lengths, and the ends of the positive output plate (2-3) and the negative output plate (2-4) are respectively provided with a vertically arranged connecting part.

8. A high power density motor controller for electric vehicles as claimed in claim 1, wherein, The current sensor assembly (5) and the thin film capacitor (2) are respectively arranged on both sides of the water tank (1-1-3) along the arrangement direction of the terminals of the power module (1-3), and the drive control board (3) is arranged above the power module (1-3) and is electrically connected with the signal terminals of the power module (1-3).

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