Motor controller and motor having the same

Abstract

The present application provides a motor controller and a motor having the same, comprising a housing and a power device, wherein the housing has a heat dissipation area, the power device is arranged in the housing, and the power device and the heat dissipation area are connected by a fixed structure. According to the motor controller and the motor having the same of the present application, the heat dissipation of the power device can be effectively ensured.

Description

Technical Field

[0001] The present application belongs to the field of motor technology, and specifically relates to a motor controller and a motor having the same. Background Art

[0002] At present, the motor controller is composed of several hardware circuits, including interface circuit, power circuit, MCU peripheral circuit, sampling circuit, Hall circuit, etc.; the Hall circuit places the Hall next to the motor rotor to obtain the position signal of the motor rotor, which is input into the MCU circuit through collection and analysis, and then the rotor position is judged to realize the analysis of the motor position, and the power circuit is further controlled to realize the variable frequency control of the motor; the Hall position is related to the good or bad operation of the motor. Placing it directly next to the motor rotor will affect the normal operation of the Hall, thereby affecting the operation of the motor; the power circuit is composed of 6 MOSFETs. In the process of energy conversion, the current flows through the power device, which will generate energy loss and present it in the form of heat. The specific manifestation is the heating of the power device and the sharp increase in surface temperature; excessive temperature will seriously damage the performance of the power device, reduce the reliability and service life of the system, and in severe cases cause device failure and damage to the entire controller.

[0003] However, the traditional heat dissipation method is to add a heat sink to each power device, which requires a large installation surface, occupies a large PCB board area, has low installation efficiency, and has high use costs. At the same time, when placing power, a single heat sink is large in size and occupies a large space. When designing a high-power density motor, there is a large space requirement, which is not suitable for the application of high-power density motors; another method is to use the end cover surface of the motor for heat dissipation, that is, to place the heat dissipation surface of the MOSFET close to the end cover surface for heat dissipation. The end cover surface heat dissipation has a large heat dissipation distance, and high thermal conductivity heat dissipation materials need to be used between the heat dissipation gaps, which is costly; at the same time, in a high-vibration and high-acceleration use environment, the structure of the motor will produce elastic deformation under the vibration environment, causing the heat dissipation gap to expand, affecting the heat dissipation effect; whether adding a heat sink or using end face heat dissipation, the heat dissipation distance control accuracy is poor. In a high-vibration environment, the heat dissipation distance will increase with the increase in vibration, which will expand the heat dissipation gap, affect the heat dissipation effect, and reduce the motor performance.

[0004] Therefore, how to provide a motor controller that can effectively ensure the heat dissipation of power devices and a motor having the same has become an urgent problem that technicians in this field need to solve. Summary of the invention

[0005] Therefore, the technical problem to be solved by the present application is to provide a motor controller and a motor having the same, which can effectively ensure the heat dissipation of power devices.

[0006] In order to solve the above problems, the present application provides a motor controller, comprising:

[0007] The housing has a heat dissipation area.

[0008] and a power device, wherein the power device is arranged in the shell, and the power device is connected to the heat dissipation area through a fixed structure.

[0009] Furthermore, the power device includes a field effect unit group, each field effect unit group includes two field effect units; the fixing structure includes a clamping structure, and the clamping structure clamps the two field effect units in the same group to the heat dissipation area at the same time.

[0010] Furthermore, the clamping structure includes a first clamping component and a second clamping component; the first clamping component is arranged in the shell and connected to the heat dissipation area; the second clamping component includes a main body structure, which has a through hole, and the first clamping component is clamped with the second clamping component through the through hole, and the main body structure is stopped at the side of the two field effect units in the same group away from the shell.

[0011] Furthermore, the body structure has an arc-shaped structure protruding in a direction away from the power device.

[0012] Further, the number of the arc structures is set to two;

[0013] And / or, the first clamping member is arranged between two field effect units in the same group;

[0014] And / or, there is a gap between the first clamping component and two field effect units in the same group.

[0015] Furthermore, the heat dissipation surface of the power device faces the heat dissipation area, and a heat conductive material is provided and filled between the heat dissipation surface and the heat dissipation area.

[0016] Furthermore, the motor controller also includes a circuit board and a power connection structure connected to the stator winding; a connection structure is provided on the circuit board, the connection structure is electrically connected to the power connection structure, and the connection structure is electrically connected to the circuit board.

[0017] Furthermore, the power connection structure includes a power connection sheet; the connection structure has a wiring slot, the wiring slot has an entrance, and the wiring slot has two conductive sheets arranged opposite to each other. The power connection sheet can enter the wiring slot through the entrance and contact the two conductive sheets.

[0018] Furthermore, the two conductive sheets each have a bending area that bends in a direction approaching each other, the bending areas of the two conductive sheets are arranged opposite to each other, and the connecting sheet can be electrically connected to the bending areas of the two conductive sheets.

[0019] Furthermore, the shell is provided with wire holes, and the positions and numbers of the wire holes correspond to those of the connection structures;

[0020] And / or, the power connection structure includes a U-phase power connection structure, a V-phase power connection structure and a W-phase power connection structure;

[0021] And / or, the number of the connection structures corresponds to the number of the power connection structures.

[0022] Furthermore, the motor controller also includes a Hall element, and a mounting groove is provided on the shell, and the Hall element is arranged in the mounting groove.

[0023] Furthermore, the motor controller also includes a heat-insulating cavity and a rotor assembly, and the rotor assembly is arranged in the heat-insulating cavity.

[0024] Furthermore, a mounting cylinder is provided on the shell, and a heat-insulating cavity is formed inside the mounting cylinder; and / or, the rotor assembly includes a rotor body and a bearing structure.

[0025] According to another aspect of the present application, a motor is provided, including a motor controller, and the motor controller is the above-mentioned motor controller.

[0026] The motor controller and the motor with the same provided by the present application fix the power device on the heat dissipation zone, which can achieve stable fixation and avoid the generation of large stress in a high vibration environment to damage the power device, and keep the heat dissipation gap within a reasonable control range. In addition, the heat dissipation zone is set on the housing of the present application to save the installation of the radiator and expand the heat dissipation area of ​​the power device. The present application can effectively ensure the heat dissipation of the power device. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 A schematic diagram of the structure of a housing according to an embodiment of the present application;

[0028] Figure 2 A schematic diagram of the installation structure of the power device according to an embodiment of the present application;

[0029] Figure 3 A schematic diagram of the installation structure of the power device according to an embodiment of the present application;

[0030] Figure 4 A schematic diagram of the structure of a housing according to an embodiment of the present application;

[0031] Figure 5 A schematic diagram of the structure of a housing according to an embodiment of the present application;

[0032] Figure 6 This is a schematic diagram of the connection structure between the housing and various components of an embodiment of the present application;

[0033] Figure 7 This is a schematic structural diagram of a second clamping member according to an embodiment of the present application;

[0034] Figure 8 This is a schematic diagram of the installation structure of the Hall element in the embodiment of the present application;

[0035] Fig. 9 This is a schematic diagram of the structure of the circuit board of the embodiment of the present application;

[0036] Fig.10 This is a structural diagram of the connection structure of an embodiment of the present application.

[0037] The reference numerals are as follows:

[0038] 1. Shell; 11. Wire hole; 12. Mounting groove; 13. Mounting tube; 2. Power device; 21. Field effect unit; 31. First clamping piece; 32. Second clamping piece; 321. Arc structure; 322. Through hole; 4. Circuit board; 41. Connection structure; 411. Conductive sheet; 5. Hall element. DETAILED DESCRIPTION

[0039] See also Figure 1-10 As shown, a motor controller includes a housing 1 and a power device 2. The housing 1 has a heat dissipation area. The power device 2 is arranged in the housing 1, and the power device 2 is connected to the heat dissipation area through a fixed structure. The power device 2 is fixed on the heat dissipation area, which can not only achieve stable fixation, but also avoid the generation of large stress in a high vibration environment to damage the power device 2, and keep the heat dissipation gap within a reasonable control range. In addition, the heat dissipation area is set on the housing 1 in this application, which saves the installation of the radiator, expands the heat dissipation area of ​​the power device 2, and can effectively ensure the heat dissipation of the power device 2. The problem of heat dissipation of the motor is solved, which makes the heat dissipation method of the controller power device 2 complex to install, low installation efficiency, large space occupied by the motor, and high cost of use. The present application solves the problem of heat dissipation of the motor, which makes the heat dissipation method of the controller power device 2 complex to install, low installation efficiency, large space occupied by the motor, and high cost of use. The present application solves the problem of heat dissipation of the motor, which makes the heat dissipation method of the controller power device 2 complex to install, low installation efficiency, large space occupied by the motor, and high cost of use. The present application solves the problem of heat dissipation of the motor in a high vibration environment, because the structure of the motor will produce elastic deformation in the vibration environment, causing the heat dissipation gap to expand, affecting the heat dissipation effect. The housing 1 forms an electrical box, and the heat dissipation platform processed in the heat dissipation area of ​​the electrical box is used as the heat dissipation surface. The power devices 2 on the motor control board are centrally arranged on one side of the PCB circuit board 4. Because the power devices 2 generate heat, the present application arranges the power devices 2 on the side of the PCB circuit board 4 close to the electrical box, which can control the heat energy thereof and prevent heat from limiting or damaging the performance of the motor controller.

[0040] The present application also discloses some embodiments, the power device 2 includes a group of field effect units 21, each group of field effect units 21 includes two field effect units 21; the fixing structure includes a clamping structure, the clamping structure clamps two field effect units 21 of the same group to the heat dissipation area at the same time, and the power device 2 is firmly fixed to the heat dissipation area through the clamping structure, thereby reducing the heat dissipation gap. Because the field effect units 21 of the power device 2 are in groups of two, three clamping structures need to be designed in the present application to achieve the fixing of six field effect units 21 of the power device 2.

[0041] The present application also discloses some embodiments, wherein the clamping structure includes a first clamping member 31 and a second clamping member 32; the first clamping member 31 is disposed in the housing 1 and connected to the heat dissipation zone; the second clamping member 32 includes a body structure, on which a through hole 322 is provided, and the first clamping member 31 is clamped with the second clamping member 32 through the through hole 322, and the body structure is stopped at the side of the two field effect units 21 in the same group away from the housing 1. The second clamping member 32 is a metal buckle, and the combination of the first clamping member 31 and the metal buckle tightly attaches the power device 2 to the heat dissipation zone of the housing 1, thereby enhancing the heat dissipation effect of the power device 2 and also enhancing the vibration resistance. The first clamping member 31 is a convex key, and the longitudinal section of the convex key is arrow-shaped. Because the DC motor generally uses a three-phase full-bridge circuit, the power devices 2 are arranged separately in groups of two. The first clamping member 31 includes a connecting rod and an arrow-shaped hook, the hook is located at the first end of the connecting rod, and the second end of the connecting rod is connected to the heat dissipation area. The hook needs to be larger than 1 mm of the second clamping structure through hole 322 to meet the requirements of the convex key fixing the metal buckle. The cross-sectional shape of the through hole 322 of the second clamping structure includes a triangular shape. The second clamping member 32 is a metal buckle.

[0042] The present application also discloses some embodiments, in which the main body structure has an arc structure 321 protruding in a direction away from the power device 2. The arc structure 321 of the metal buckle is used to fix and buckle the power device 2 through the first clamping member 31, further enhancing the anti-vibration performance.

[0043] The present application also discloses some embodiments, in which the number of arc structures 321 is set to two; the main body of the second clamping member 32 is an arc structure 321, and after the middle through hole 322 passes through the convex key, the arrow structure of the convex key fixes the metal buckle in reverse, and the power device 2 is tightly fixed on the heat dissipation area by using the end of the metal buckle; at the same time, when the inverted triangle structure of the metal buckle and the convex key vibrates up and down in the electrical box, the double convex structure of the metal buckle can filter out the impact of strong vibration on the power device 2, resulting in an increase in the heat dissipation gap, and effectively controlling the distance of the heat dissipation gap, thereby ensuring that sufficient heat dissipation capacity can still be maintained in a high vibration environment. With good heat dissipation performance, the surface temperature of the power device 2 is maintained at a relatively low level range, so that the power device 2 can work for a long time in a suitable temperature range, reducing the system's requirements for the performance indicators of the power device 2, and using a low-cost power device 2. A higher power usage can also be obtained, thereby improving the competitiveness of product costs and ensuring stable operation of the motor at high speeds. The length of the metal buckle is 22mm, the width is 10mm, and the thickness is 0.5mm. This size can better fix the TO-220 package type MOS; if there are other package types of power devices 2 (MOS, IGBT), the package types are DPAK, D2PAK, IPAK, TO-220SIS, TO-247 and other types, the shape of the metal buckle needs to be increased or decreased simultaneously.

[0044] The present application also discloses some embodiments, in which the first clamping member 31 is disposed between two field effect units 21 in the same group;

[0045] The present application also discloses some embodiments, there is a gap between the first clamp 31 and the two field effect units 21 in the same group, that is, the spacing between the two field effect units 21 in the same group needs to be greater than the width of the first clamp 31, and the gap between each MOS and the first clamp 31 is more than 1mm; the heat dissipation area of ​​a single MOS is 10*10mm. The area of ​​the heat dissipation zone needs to be greater than the heat dissipation area of ​​the MOS, and the heat dissipation area required for the projection of a single MOS is 15*15mm, so as to increase the heat dissipation capacity of the MOS; the length of the first clamp 31, i.e., the convex key, is 10mm, the width is 1mm, and the height should be higher than the thickness of the MOS by 2.1mm. The first clamp 31 includes a connecting rod and an arrow-shaped hook, the hook is located at the first end of the connecting rod, the second end of the connecting rod is connected to the heat dissipation zone, and the distance between the hook and the heat dissipation zone is more than 2.8mm (height 2.1mm + thickness of the second clamp 32 0.5mm).

[0046] The present application also discloses some embodiments, the heat dissipation surface of the power device 2 faces the heat dissipation zone, and a heat conductive material is arranged between the heat dissipation surface and the heat dissipation zone. After the power device 2 is connected to the heat dissipation zone, the gap between the heat dissipation zones of the power device 2 is controlled to be between 0.5mm and 1mm, and a heat conductive material, such as a heat conductive silicone material, is filled between the gaps. The air between the gaps is replaced by a silicone material with good thermal conductivity, which can enhance the heat dissipation performance; the heat conductive material is generally a heat conductive silicone and a heat conductive paste. When using a heat conductive paste material, the use area of ​​the heat conductive paste must be greater than the total heat dissipation area of ​​6 MOS, at least 6*225 square millimeters, and the maximum area shall not exceed the area of ​​the heat dissipation zone.

[0047] The present application also discloses some embodiments, in which the motor controller further includes a circuit board 4 and a power connection structure connected to the stator winding; a connection structure 41 is provided on the circuit board 4, the connection structure 41 is electrically connected to the power connection structure, and the connection structure 41 is electrically connected to the circuit board 4.

[0048] The present application also discloses some embodiments, in which the power connection structure includes a power connection sheet; the connection structure 41 has a wiring slot, the wiring slot has an entrance, and the wiring slot has two conductive sheets 411 arranged opposite to each other. The power connection sheet can enter the wiring slot through the entrance and contact the two conductive sheets 411.

[0049] The present application also discloses some embodiments, in which the two conductive sheets 411 have bending areas that bend toward each other, the bending areas of the two conductive sheets 411 are arranged opposite to each other, and the connecting sheet can be electrically connected to the bending areas of the two conductive sheets 411 . The bending area is an arc structure 321, which can be a continuous double-arc structure 321 or a continuous three-arc structure 321, or a continuous multi-arc structure 321. An arc-shaped metal surface is designed on the inside of the wiring slot, and there is a gap between the arc-shaped metal surfaces. The arc structure 321 is a semicircular structure constructed of two metal sheets with a radius of 2.5mm and a thickness of 0.5mms, which is tightly connected to the inner wall of the needle seat. The arc structures 321 on the left and right sides form a double-arc three-dimensional structure; after the stator core is installed, the three-phase winding contact plate passes through the electrical box and the PCB circuit board 4, and contacts the double-arc metal surface of the needle seat. The metal elastic force generated by the arc-shaped metal surface after extrusion is used to connect the contact plate and the needle seat to realize electrical signal connection. After the double-arc metal surface is deformed under force, the contact area between the two can be expanded, the contact resistance between the two can be reduced, and electric sparks can be avoided; at the same time, this method is simple to operate, does not require welding or bolt fixing, and can improve installation efficiency.

[0050] The present application also discloses some embodiments, wherein the housing 1 is provided with wire holes 11, and the positions and numbers of the wire holes 11 and the connection structures 41 correspond to each other; the wire holes 11 are provided on the housing 1, which facilitates the connection between the controller and the three-phase wires of the motor, saves the motor installation time, and also saves the internal space of the motor. There are three wire holes 11 on the housing 1, and three pin connection structures 41 at the corresponding positions of the circuit board 4 are used to connect with the three-phase power connection plate of the motor; the other end of the power connection plate is connected to the stator winding; there are four rectangular structures at the bottom of the installation structure, with a length, width and height of 1*1*3mm respectively, which are used to connect with the PCB circuit board 4, taking into account both fixation and electrical signal connection, and the top is a hollow rectangular structure, with an overall size of 8*6*35mm in length, width and height, and the height is the length of the power connection plate after it extends out of the PCB circuit board 4.

[0051] And / or, the power connection structure includes a U-phase power connection structure, a V-phase power connection structure and a W-phase power connection structure; the wire hole 11 of the electrical box and the connection structure 41 on the circuit board 4 realize the three-phase line connection between the controller and the motor, simplify the installation of the motor and the controller, and save the internal space of the motor. The close contact between the two also eliminates the welding step, making the operation easier.

[0052] And / or, the number of the connection structures 41 corresponds to the number of the power connection structures.

[0053] The present application also discloses some embodiments, the motor controller also includes a Hall element 5, and the housing 1 is also provided with a mounting groove 12, and the Hall element 5 is arranged in the mounting groove 12. The position of the mounting groove 12 corresponds to the position of the Hall element 5 on the circuit board 4. A mounting groove 12 is designed on the electrical box, which is 40 mm long, 10 mm wide, and 30 mm deep. When the welded circuit board 4 is assembled to the electrical box, the Hall element 5 can be well inserted into the mounting groove 12. The mounting groove 12 design can position the Hall element at a fixed position, improve the accuracy of the motor operation, and also prevent the influence of friction and vibration on the Hall, and avoid the reduction of control accuracy caused by the inaccuracy of the Hall sampling signal; in a high vibration environment, the mounting groove 12 can limit the swing range of the Hall element 5 on the controller, and has a supporting effect. The mounting groove 12 can make the Hall device better fixed on the motor, and at the same time more effectively utilize the space of the motor, thereby achieving the purpose of reducing costs. The mounting groove 12 stabilizes the Hall device on the controller and saves the use space for the motor.

[0054] The present application also discloses some embodiments, wherein the motor controller further comprises a heat-insulating cavity and a rotor assembly, wherein the rotor assembly is disposed in the heat-insulating cavity. The heat-insulating cavity can separate the motor bearing from the controller, effectively isolating the heat generated by the bearing during operation, reducing the heat transfer between the two, avoiding the mutual influence of the heat between the two, improving the heat dissipation efficiency of the motor itself, increasing the service life of the motor, and avoiding the influence on the operation of the controller.

[0055] The present application also discloses some embodiments, in which a mounting cylinder 13 is provided on the housing 1, and a heat-insulating cavity is formed inside the mounting cylinder 13; and / or the rotor assembly includes a rotor body and a bearing structure. The cross-section of the mounting cylinder 13 is circular, and one end of the mounting cylinder 13 is connected to the housing 1. The cross-sectional diameter of the mounting cylinder 13 is 24 mm, which can meet the installation dimensions of the bearing. When the motor is installed, the rotor body and the bearing are passed through the middle opening position. The design of this sleeve can well separate the motor rotor, the bearing and the components on the controller, which effectively avoids the heat generated by the rotation of the rotor bearing and the influence on the controller, so that the power device 2 works within a suitable working environment temperature range.

[0056] According to an embodiment of the present application, a motor is provided, including a motor controller, and the motor controller is the above-mentioned motor controller.

[0057] It is easy for those skilled in the art to understand that, under the premise of no conflict, the above-mentioned advantageous methods can be freely combined and superimposed.

[0058] The above are only preferred embodiments of the present application and are not intended to limit the present application. Any modifications, equivalent replacements and improvements made within the spirit and principles of the present application shall be included in the protection scope of the present application. The above are only preferred implementations of the present application. It should be pointed out that for ordinary technicians in this technical field, several improvements and variations can be made without departing from the technical principles of the present application, and these improvements and variations should also be regarded as the protection scope of the present application.

Claims

1. A motor controller, It is characterized in that include: A housing (1), wherein the housing (1) has a heat dissipation area, and a power device (2), wherein the power device (2) is arranged in the housing (1), and the power device (2) is connected to the heat dissipation area via a fixed structure; The power device (2) comprises a group of field effect units (21), each group of the field effect units (21) comprising two field effect units (21); the fixing structure comprises a clamping structure, the clamping structure clamps the two field effect units (21) of the same group to the heat dissipation zone at the same time; the clamping structure comprises a first clamping member (31) and a second clamping member (32); the first clamping member (31) is arranged in the shell (1) and connected to the heat dissipation zone; the second clamping member (32) comprises a body structure, the body structure is provided with a through hole (322), the first clamping member (31) is clamped with the second clamping member (32) through the through hole (322), and the body structure is stopped at a side of the two field effect units (21) of the same group away from the shell (1); the body structure has an arc-shaped structure (321) protruding in a direction away from the power device (2); the cross-sectional shape of the through hole (322) of the second clamping structure comprises a triangular shape.

2. The motor controller according to claim 1, It is characterized in that The number of the arc-shaped structures (321) is set to two; And / or, the first clamping member (31) is arranged between two field effect units (21) in the same group; And / or there is a gap between the first clamping member (31) and the two field effect units (21) in the same group.

3. The motor controller according to claim 1, It is characterized in that The heat dissipation surface of the power device (2) faces the heat dissipation area, and a heat conducting material is provided and filled between the heat dissipation surface and the heat dissipation area.

4. The motor controller according to claim 1, It is characterized in that The motor controller further comprises a circuit board (4) and a power connection structure connected to the stator winding; a connection structure (41) is provided on the circuit board (4), the connection structure (41) is electrically connected to the power connection structure, and the connection structure (41) is electrically connected to the circuit board (4).

5. The motor controller according to claim 4, It is characterized in that The power connection structure comprises a power connection sheet; the connection structure (41) has a wiring slot, the wiring slot has an entrance, and the wiring slot has two conductive sheets (411) arranged opposite to each other, and the power connection sheet can enter the wiring slot through the entrance and contact the two conductive sheets (411).

6. The motor controller according to claim 5, It is characterized in that The two conductive sheets (411) each have a bending area that bends in a direction approaching each other, the bending areas of the two conductive sheets (411) are arranged opposite to each other, and the connecting sheet can be electrically connected to the bending areas of the two conductive sheets (411).

7. The motor controller according to claim 4, It is characterized in that The housing (1) is provided with wire holes (11), and the positions and numbers of the wire holes (11) correspond to those of the connecting structures (41); And / or, the power connection structure includes a U-phase power connection structure, a V-phase power connection structure and a W-phase power connection structure; And / or, the number of the connection structures (41) corresponds to the number of the power connection structures.

8. The motor controller according to claim 1, It is characterized in that The motor controller further comprises a Hall element (5), and the housing (1) is further provided with a mounting groove (12), wherein the Hall element (5) is arranged in the mounting groove (12).

9. The motor controller according to claim 1, It is characterized in that The motor controller also includes a heat-insulating cavity and a rotor assembly, wherein the rotor assembly is disposed in the heat-insulating cavity.

10. The motor controller according to claim 9, It is characterized in that The housing (1) is provided with a mounting cylinder (13), the interior of the mounting cylinder (13) forming the heat insulation cavity; and / or the rotor assembly comprises a rotor body and a bearing structure.

11. A motor, comprising a motor controller, It is characterized in that The motor controller is the motor controller according to any one of claims 1-10.

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