A highly integrated electrical device for high power motor controller

Abstract

The present invention relates to a highly integrated electrical device for a high-power motor controller, comprising a busbar plate, a film capacitor, a power module assembly, a control board, a three-phase output plate, a drive board, and a three-phase plastic-coated bracket, wherein the power module assembly comprises a power module and a radiator; the film capacitor and the drive board are respectively arranged on opposite sides of the power module assembly, the input end of the film capacitor passes through a magnetic ring assembly and is connected to the busbar plate, the drive board is fixed on the three-phase plastic-coated bracket and is connected to the control board, the radiator is fixedly connected to the three-phase plastic-coated bracket, the input end of the three-phase plastic-coated bracket is electrically connected to the output end of the power module, and the input end of the three-phase output plate passes through a current sensor and is electrically connected to the output end of the three-phase plastic-coated bracket. Compared with the prior art, the present invention has the advantages of high integration, modular structure, compact structure, and small size.

Description

Technical Field

[0001] The invention relates to the field of motor controllers, and in particular to a highly integrated electrical device for a high-power motor controller. Background Art

[0002] The motor controller for traditional new energy vehicles generally includes busbar plates, magnetic rings, magnetic ring supports, film capacitors, current sensors, IGBTs, drive boards, shielding boards, control boards and other components. The busbar plates, magnetic ring supports, film capacitors and IGBTs are independently assembled inside the controller box, which increases the layout area inside the box and has a low integration level, resulting in a large length and width of the box and inconvenient assembly of parts. Since the traditional heat dissipation water channel is arranged on the bottom of the box, the complexity of the box structure and processing technology is increased, which increases the manufacturing cost of the box. Summary of the invention

[0003] The purpose of the present invention is to overcome the defects of the above-mentioned prior art and provide a highly integrated electrical device for a high-power motor controller.

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

[0005] A highly integrated electrical device for a high-power motor controller comprises a busbar plate, a film capacitor, a power module assembly, a control board, a three-phase output plate, a drive board, and a three-phase plastic-coated bracket, wherein the power module assembly comprises a power module and a radiator; the film capacitor and the drive board are respectively arranged on two opposite sides of the power module assembly, the input end of the film capacitor is connected to the busbar plate through a magnetic ring assembly, the drive board is fixed on the three-phase plastic-coated bracket and connected to the control board, the radiator is fixedly connected to the three-phase plastic-coated bracket, the input end of the three-phase plastic-coated bracket is electrically connected to the output end of the power module, and the input end of the three-phase output plate is electrically connected to the output end of the three-phase plastic-coated bracket after passing through a current sensor.

[0006] Preferably, the busbar plate comprises a front insulating paper, a positive copper busbar, an intermediate insulating paper, a negative copper busbar, and a back insulating paper which are stacked in sequence.

[0007] Preferably, the upper and lower edges of the front insulating paper, the middle layer insulating paper and the back insulating paper all exceed the positive electrode copper busbar by a certain height, and the exceeding parts are hot-pressed together using glue.

[0008] Preferably, the heat sink comprises a plurality of positioning cavities arranged in double layers, and the power modules are installed in the positioning cavities.

[0009] Preferably, a water inlet and a water outlet are respectively provided at both ends of the radiator, a heat dissipation water channel is distributed between the two layers of positioning cavities, and the water inlet, the heat dissipation water channel and the water outlet are interconnected.

[0010] Preferably, the magnetic ring assembly comprises a magnetic ring support and a magnetic ring, the magnetic ring support is provided with a waist-shaped groove, the waist-shaped groove is provided with a terminal outlet hole, and the magnetic ring is sealed in the waist-shaped groove.

[0011] Preferably, a threaded hole is provided on the magnetic ring support, and the input end of the film capacitor is electrically connected to the output end of the busbar plate after passing through the terminal outlet hole, and the two are fixed to the magnetic ring support together through the threaded hole.

[0012] Preferably, the three-phase plastic-coated bracket is provided with a plurality of pillars and threaded holes, and the three-phase plastic-coated bracket is provided with a through rectangular hole and a rectangular notch; the rectangular holes are provided in plurality, corresponding to the positions of the power modules respectively, and the rectangular notch corresponds to the position of the current sensor.

[0013] Preferably, the control panel is arranged on the upper side of the radiator through a column.

[0014] Preferably, columns are provided on multiple sides of the radiator.

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

[0016] 1. The components of this device are interconnected to form a whole, with a compact structure and high integration, which is convenient for direct assembly in the controller box or removal from the box.

[0017] 2. The radiator integrates the water inlet, outlet, cooling channel and positioning cavity, with high integration. It adopts modular design, and the number of positioning cavities can be designed according to the number of power modules, and the structure has strong adaptability. There are columns on multiple sides of the radiator, and there are threaded holes on the columns, so they can also be used as brackets to fix other components.

[0018] 3. The front insulating paper, positive copper busbar, middle insulating paper, negative copper busbar and back insulating paper of the busbar plate are stacked in sequence to achieve electrical insulation between the positive copper busbar and the negative copper busbar; the upper and lower edges of the three insulating papers are hot-pressed together with glue to achieve the connection between the insulating paper and the positive copper busbar and the negative copper busbar. This insulation method has simple processing technology, low cost, small quality and volume.

[0019] 4. The three-phase plastic-coated bracket has three copper bars coated with plastic inside the bracket, and there are protruding pillars and threaded holes in the front of the bracket, so that it can both flow large current and fix the drive board. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a structural schematic diagram of the present invention;

[0021] Figure 2 It is a schematic diagram of the structure of the busbar plate in the present invention;

[0022] Figure 3 It is a structural schematic diagram of the magnetic ring support in the present invention;

[0023] Figure 4 It is a schematic diagram of the structure of the film capacitor in the present invention;

[0024] Figure 5 It is a schematic structural diagram of the three-phase plastic-coated bracket in the present invention.

[0025] Markings in the figure: 1 is the busbar plate, 2 is the magnetic ring support, 3 is the magnetic ring, 4 is the film capacitor, 5 is the power module, 6 is the heat sink, 7 is the control board, 8 is the current sensor, 9 is the three-phase output plate, 10 is the drive board, 11 is the three-phase plastic-coated bracket; 1-1 is the positive copper busbar, 1-2 is the negative copper busbar, 1-3 is the front insulating paper, 1-4 is the middle layer insulating paper, 1-5 is the back insulating paper; 2-1 is the terminal outlet hole, 2-2 is the waist-shaped groove; 4-1 is the input end of the film capacitor, 4-2 is the output end of the film capacitor; 9-1 is the input end of the three-phase plastic-coated bracket, 9-2 is the output end of the three-phase plastic-coated bracket. DETAILED DESCRIPTION

[0026] The present invention is described in detail below in conjunction with the accompanying drawings and specific embodiments. This embodiment is implemented based on the technical solution of the present invention, and provides a detailed implementation method and specific operation process, but the protection scope of the present invention is not limited to the following embodiments.

[0027] like Figure 1 As shown, the present application proposes a highly integrated electrical device for a high-power motor controller, including a busbar plate 1, a thin film capacitor 4, a power module assembly, a control board 7, a three-phase output plate 9, a drive board 10, a three-phase plastic-coated bracket 11, a magnetic ring assembly, and a current sensor 8. The power module assembly includes a power module 5 and a heat sink 6.

[0028] The film capacitor 4 and the driving board 10 are respectively arranged on opposite sides of the power module assembly, and the input terminal 4-1 of the film capacitor passes through the magnetic ring assembly and is connected to the busbar plate 1. The driving board 10 is fixed on the three-phase plastic-coated bracket 11 and is connected to the control board 7. The radiator 6 is fixedly connected to the three-phase plastic-coated bracket 11, and the input terminal 9-1 of the three-phase plastic-coated bracket is electrically connected to the output terminal of the power module 5. The input terminal of the three-phase output plate 9 passes through the current sensor 8 and is electrically connected to the output terminal 9-2 of the three-phase plastic-coated bracket. The output terminal of the three-phase output plate 9 is electrically connected to other equipment to output three-phase alternating current. The control board 7 is arranged on the upper side of the radiator 6 through a column.

[0029] The radiator 6 includes a plurality of positioning cavities arranged in a double layer, and the power module 5 is installed in the positioning cavity. The left and right ends of the bottom surface of the radiator 6 are respectively provided with a water inlet and a water outlet, and a heat dissipation water channel is distributed between the two layers of positioning cavities. The water inlet, the heat dissipation water channel, and the water outlet are mutually connected, and the heat dissipation water channel is completely sealed except for the water inlet and the water outlet. Columns are provided on multiple sides of the radiator 6. In this embodiment, the radiator 6 has three positioning cavities, and the cross-section of the positioning cavity is approximately rectangular and penetrates from front to back. The first layer is provided with one positioning cavity, which is located below the heat dissipation water channel, and the second layer is provided with two positioning cavities, which are located above the heat dissipation water channel. There are three power modules 5 in total, which are respectively installed in the three positioning cavities, and ensure that the heat dissipation surface of the power module 5 is close to one side of the heat dissipation water channel of the radiator 6. The number of positioning cavities can be flexibly changed according to the number of power modules 5. When the power module 5 is working, most of the heat is transferred to the radiator 6 through the heat dissipation surface. The coolant enters the heat dissipation channel from the water inlet, takes away the heat on the radiator 6, and flows out from the water outlet. There are 8 columns distributed on the top surface of the radiator 6, and the columns are 0.5mm higher than the surrounding plane. Each column has a threaded hole. The control board 7 is on the column, and the control board 7 is connected to the column by screws. There are 4 threaded holes in the front of the radiator 6, which are connected to the three-phase plastic-coated bracket 11 by screws.

[0030] like Figure 2 As shown, the busbar plate 1 is an L-shaped bending structure as a whole, including front insulation paper 1-3, positive copper bar 1-1, middle insulation paper 1-4, negative copper bar 1-2, and back insulation paper 1-5 stacked in sequence. The upper and lower edges of the front insulation paper 1-3, middle insulation paper 1-4, and back insulation paper 1-5 all exceed the positive copper bar 1-1 by a certain height, which exceeds 5mm in this embodiment, and the exceeding part is hot-pressed together with glue to achieve connection between the insulation paper and the positive copper bar 1-1 and the negative copper bar 1-2.

[0031] like Figure 3 As shown, the magnetic ring assembly includes a magnetic ring support 2 and a magnetic ring 3. The magnetic ring support 2 is provided with a waist-shaped groove 2-2, and the waist-shaped groove 2-2 is provided with a terminal outlet 2-1. The magnetic ring 3 is sealed in the waist-shaped groove 2-2 by silicone. A threaded hole is provided on the magnetic ring support 2. A two-phase high-voltage current is input from the input end of the busbar plate 1. After the input end 4-1 of the film capacitor passes through the terminal outlet 2-1, it is electrically connected to the output end of the busbar plate 1, and the two are fixed to the magnetic ring support 2 together through the threaded hole.

[0032] like Figure 4 As shown, the input end 4-1 of the film capacitor is a long positive and negative busbar structure. The output end 4-2 of the film capacitor is a short three-pair positive and negative busbar structure, and each pair of positive and negative busbars is electrically connected to an input end of a power module 5 by laser welding.

[0033] like Figure 5 As shown, the three-phase plastic-coated bracket 11 is provided with a plurality of pillars and threaded holes, and the three-phase plastic-coated bracket 11 is provided with a through rectangular hole and a rectangular notch. There are three rectangular holes, which correspond to the positions of the power module 5 respectively, to prevent interference with the output end and signal pin of the power module 5. The rectangular notch corresponds to the position of the current sensor 8 in the lower right corner, to prevent interference with the current sensor 8. The output end of the power module 5 is electrically connected to the input end 9-1 of the three-phase plastic-coated bracket by laser welding, and the signal pin of the power module 5 is electrically connected to the driver board 10 by wave soldering.

[0034] The film capacitor 4, the power module 5, and the three-phase plastic-coated bracket 11 are electrically connected by laser welding, thereby saving space.

[0035] The installation process of the device is as follows:

[0036] 1. Install the power module 5 on the radiator 6: During the installation process, place the power module 5 in front of the positioning cavity so that the heat dissipation surface of the power module 5 is opposite to one side of the heat dissipation channel of the radiator 6. Apply force perpendicular to the cross-section of the power module 5 to make it slide backward along the upper cavity until only the wiring terminals of the power module 5 are exposed outside the cavity; after the installation is completed, ensure that the power module 5 is clamped inside the positioning cavity without looseness, and the heat dissipation surface of the power module 5 is tightly fitted with the inner surface of the positioning cavity.

[0037] 2. Place the magnetic ring 3 in the waist-shaped groove 2-2 of the magnetic ring support 2 and cure it with silicone.

[0038] 3. Pass the magnetic ring support 2 equipped with the magnetic ring 3 through the input terminal 4-1 of the film capacitor, so that the output end of the busbar plate 1 and the input terminal 4-1 of the film capacitor are stacked, and fix the two on the magnetic ring support 2 by bolts.

[0039] 4. Stack the output end 4-2 of the film capacitor and the input end of the power module 5, and ensure that the two end surfaces are aligned, and then weld them into one by laser welding.

[0040] 5. Fix the current sensor 8 to the lower right corner of the front side of the radiator 6 with screws.

[0041] 6. Place the output end of the power module 5 and the input end 9-1 of the three-phase plastic-coated bracket in a stacked manner, and ensure that the end faces of both sides are aligned. Then fix the three-phase plastic-coated bracket 11 to the front of the radiator 6 with screws, and weld the output end of the power module 5 and the input end of the three-phase plastic-coated bracket 11 into one by laser welding.

[0042] 7. Pass the input end of the three-phase output electrode plate 9 through the current sensor 8 and fix it to the output end 9-2 of the three-phase plastic-coated bracket with screws.

[0043] 8. The driving board 10 is fixed to the front of the three-phase plastic-coated bracket 11 by means of bolts, and the signal pins of the power module 5 are welded to the corresponding positions on the driving board 10 by means of wave soldering.

[0044] 9. Fix the control board 7 on the upper side of the radiator 6, and realize the electrical connection between the control board 7 and the driving board 10 through the wiring harness.

Claims

1. A highly integrated electrical device for a high-power motor controller, comprising a busbar plate (1), a film capacitor (4), a power module assembly, a control board (7), a three-phase output plate (9), a drive board (10), and a three-phase plastic-coated bracket (11), wherein the power module assembly comprises a power module (5) and a heat sink (6); characterized in that: The film capacitor (4) and the drive board (10) are respectively arranged on two opposite sides of the power module assembly, the input end (4-1) of the film capacitor passes through the magnetic ring assembly and is connected to the busbar plate (1), the drive board (10) is fixed on the three-phase plastic-coated bracket (11) and is connected to the control board (7), the heat sink (6) is fixedly connected to the three-phase plastic-coated bracket (11), the input end (9-1) of the three-phase plastic-coated bracket is electrically connected to the output end of the power module (5), and the input end of the three-phase output plate (9) passes through the current sensor (8) and is electrically connected to the output end (9-2) of the three-phase plastic-coated bracket; The heat sink (6) comprises a plurality of positioning cavities arranged in a double layer, and the power module (5) is installed in the positioning cavity; The radiator (6) is provided with a water inlet and a water outlet at both ends, respectively, and a heat dissipation water channel is distributed between the two layers of positioning cavities, and the water inlet, the heat dissipation water channel and the water outlet are interconnected; The three-phase plastic-coated bracket (11) is provided with a plurality of pillars and threaded holes, and the three-phase plastic-coated bracket (11) is provided with a through rectangular hole and a rectangular notch; the rectangular holes are provided in plurality, corresponding to the positions of the power modules (5) respectively, and the rectangular notch corresponds to the position of the current sensor (8).

2. A highly integrated electrical device for a high-power motor controller according to claim 1, characterized in that: The busbar plate (1) comprises a front insulating paper (1-3), a positive copper busbar (1-1), an intermediate insulating paper (1-4), a negative copper busbar (1-2), and a back insulating paper (1-5) which are stacked in sequence.

3. A highly integrated electrical device for a high-power motor controller according to claim 2, characterized in that: The upper and lower edges of the front insulating paper (1-3), the middle layer insulating paper (1-4), and the back insulating paper (1-5) all exceed the positive electrode copper bus (1-1) by a certain height, and the exceeding parts are hot-pressed together using glue.

4. A highly integrated electrical device for a high-power motor controller according to claim 1, characterized in that: The magnetic ring assembly comprises a magnetic ring support (2) and a magnetic ring (3); the magnetic ring support (2) is provided with a waist-shaped groove (2-2); a terminal outlet hole (2-1) is provided in the waist-shaped groove (2-2); and the magnetic ring (3) is sealed in the waist-shaped groove (2-2).

5. A highly integrated electrical device for a high-power motor controller according to claim 4, characterized in that: The magnetic ring support (2) is provided with a threaded hole, and the input end (4-1) of the film capacitor is electrically connected to the output end of the busbar plate (1) after passing through the terminal outlet hole (2-1), and the two are fixed to the magnetic ring support (2) together through the threaded hole.

6. A highly integrated electrical device for a high-power motor controller according to claim 1, characterized in that: The control panel (7) is arranged on the upper side of the radiator (6) via a column.

7. A highly integrated electrical device for a high-power motor controller according to claim 1, characterized in that: Multiple side surfaces of the radiator (6) are provided with columns.

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