A high-power motor controller and integrated electric drive system for electric vehicles

Abstract

The application relates to a high-power motor controller for an electric vehicle and an integrated electric drive system, wherein a control panel of an integrated control device and a three-phase plastic-coated support are arranged on the top surface and one side of the long edge of a radiator, a film capacitor is arranged on the other side of the long edge of the radiator, a drive panel is vertically fixed on the three-phase plastic-coated support, three-phase output ends of a power module are electrically connected with input ends of the three-phase plastic-coated support, signal output ends of the power module are electrically connected with the drive panel, a magnetic ring assembly is sleeved on the input end of the film capacitor and is fixed on the bottom surface of a box body; a busbar pole plate is L-shaped as a whole and is arranged outside the integrated control device, one end of the busbar pole plate is located at one end of the L shape and is electrically connected with two-phase plug-in components, and the other end of the busbar pole plate is located at the other end of the L shape and is electrically connected with an input end of the integrated control device. Compared with the prior art, the application has the advantages of compact structure, light mass, small volume, high power density, high vibration resistance, convenient automatic assembly and disassembly.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of electric vehicles, in particular to a high-power motor controller for electric vehicles and an integrated electric drive system. BACKGROUND

[0002] With the continuous promotion of new energy vehicles, due to the limited arrangement of the motor controller in the vehicle, the internal components of the controller generate a large amount of heat, thus requiring the controller to have a compact structure, small mass and volume, and good heat dissipation capacity. The traditional motor controller for new energy vehicles generally includes busbars, magnetic rings, magnetic ring supports, film capacitors, current sensors, IGBTs, drive boards, shielding plates, control boards, etc. Among them, the busbars, magnetic ring supports, film capacitors, and IGBTs are independently assembled inside the controller box, and the integration level of the components is low, which increases the layout area inside the box, resulting in a large size of the box and inconvenient assembly of the parts, and the controller is too large in volume, which is insufficient in the assembly space in the vehicle. Therefore, the miniaturization and high power density of the motor controller are gradually developed, and the electric drive system of the electric vehicle is gradually developed towards the design direction of integrating the drive motor, the reduction box, and the motor controller into a three-in-one system.

[0003] The motor controller of the three-in-one electric drive design on the market is basically designed in a separate structure, and the motor controller is arranged above the motor and the reducer. The center of gravity of the motor controller is the highest in the entire three-in-one system, and during vibration, the motor controller acts as a pendulum and swings, with a much larger vibration acceleration than the motor and the reducer, which brings great risks to the reliability of the internal components of the motor controller. The existing three-in-one motor controller basically connects each component together through bolts, and each component is separate, so the integration level of the motor controller is low, the number of connecting parts is large, and the overall system has poor vibration resistance. The probability of damage during three-in-one vibration is very high, especially the motor controller is more dangerous. In addition, because the motor controller is designed in a separate structure, the volume of the motor controller is too large, the height is too high, and the power density is low, which results in a large volume of the entire three-in-one system, which is not conducive to the arrangement of the three-in-one electric drive system in the vehicle. Therefore, the first prerequisite for designing a high-power density three-in-one electric drive system is to solve the problem of high integration of the motor controller. SUMMARY

[0004] The purpose of the present application is to overcome the defects of the prior art and provide a high-power motor controller for electric vehicles and an integrated electric drive system.

[0005] The purpose of the present application can be achieved by the following technical solutions:

[0006] The utility model provides a high power motor controller for electric vehicle, including box, the bus pole plate, integrated control device, three phase output device are equipped in the box, the integrated control device includes power module, radiator, magnetic ring assembly, film capacitor, control panel, three phase plastic support, drive board, the power module is fixed in the cavity of radiator, control panel, three phase plastic support are arranged on the top surface and one side of long side of radiator respectively, the film capacitor is arranged on the other side of long side of radiator, drive board is fixed on three phase plastic support vertically, the three phase output end of power module is electrically connected with the input end of three phase plastic support, the signal output end of power module is electrically connected with drive board, the magnetic ring assembly is covered in the input end of film capacitor and is fixed on the bottom surface of box, the bus pole plate is L-shaped as a whole and is arranged on the outside of integrated control device, and one end is located at one end of L-shaped and is electrically connected with two phase inserts, and the other end is located at the other end of L-shaped and is electrically connected with the input end of integrated control device.

[0007] Preferably, the power module is provided with a plurality of, in the radiator with double layer arrangement mode.

[0008] Preferably, the box is provided with two phase inserts, low voltage inserts, respirator cover, water inlet pipe, water outlet pipe, the water inlet pipe is communicated with the water inlet of radiator, one end of the water outlet pipe is communicated with the water outlet of radiator, and the other end is communicated with the water inlet of motor casing.

[0009] Preferably, the two phase inserts and low voltage inserts are located on the front side of the box, the respirator cover is located on the left side of the box, the water inlet pipe is located on the bottom of the left side of the box, and the water outlet pipe is located on the right side of the box.

[0010] Preferably, the matching surfaces of the water inlet pipe and the water outlet pipe are respectively provided with O-rings.

[0011] Preferably, the three phase output device includes three phase pole plate, pole plate support, current sensor, three phase output pole plate, three phase terminal block, one end of the three phase pole plate is connected with the three phase output end of three phase plastic support, the other end is fixed on the pole plate support and realizes electrical connection with one end of three phase output pole plate, the other end of three phase output pole plate passes through current sensor and three phase terminal block in sequence, and then extends into the motor and is fixed on three phase terminal block with the three phase cable of motor.

[0012] Preferably, the top of the box is provided with a box cover, the top surface of the box cover includes a rectangular plane in the center, four arc surfaces are extended outward from the four edges of the rectangular plane, so that the box cover as a whole has a shape of high in the middle and low at the four corners.

[0013] The application discloses a high-power integrated electric drive system for an electric vehicle, which comprises a motor controller, a motor and a reduction gearbox.

[0014] Preferably, the right end surface of the reduction gearbox is connected with the left end surface of the motor shell through bolts, and the inside is connected with the motor rotor through a hollow shaft with internal splines to realize power transmission; the motor controller is fixed on the motor and the reduction gearbox through the supporting legs.

[0015] Preferably, the water outlet of the motor controller is communicated with the water inlet on the motor shell.

[0016] Compared with the prior art, the application has the following beneficial effects:

[0017] 1. The integrated control device integrates various components and radiators, has high integration degree, compact structure, regular shape, high utilization rate of the space in the box body, and is convenient for being directly assembled in the controller box body or taken out from the box body.

[0018] 2. The power module is arranged in a double-layer mode in the radiator, and has small occupied area.

[0019] 3. The arrangement of the radiator of the power module reduces the volume of the drive system and improves the integration degree, reduces the gravity center of the controller, thereby reducing the vibration of the drive system.

[0020] 4. The radiator is integrated in the integrated control device, compared with the traditional mode of integrating the radiator on the bottom surface of the box body, the radiator is convenient to replace, and the structure of the box body can be simplified, and the machining cost of the box body is reduced.

[0021] 5. The motor controller has compact structure and small volume, and can be integrated on the motor and the reduction gearbox, so that the overall volume of the integrated electric drive system is small. BRIEF DESCRIPTION OF DRAWINGS

[0022] Figure 1 It is a general assembly drawing of the high-power integrated electric drive system for the electric vehicle;

[0023] Figure 2 It is a structural schematic view of the motor controller;

[0024] Figure 3 It is a structural schematic view of the box body;

[0025] Figure 4 It is a structural schematic view of the integrated control device;

[0026] Figure 5 It is a structural schematic view of the three-phase output device;

[0027] Figure 6This is a schematic diagram of the structure of the top of the box lid;

[0028] Figure 7 This is a schematic diagram of the bottom of the box lid.

[0029] The diagram is labeled as follows: 1. Motor controller; 2. Motor; 3. Gearbox; 1-1. Housing; 1-2. Breather cover; 1-3. Busbar plate; 1-4. Integrated control device; 1-5. Housing cover; 1-6. Three-phase output device; 1-7. Low-voltage connector; 1-8. Two-phase connector; 1-9. Water inlet pipe; 1-1-1. Low-voltage connector interface; 1-1-2. Two-phase connector interface; 1-1-3. Water inlet; 1-1-4. Breather interface; 1-1-5. Water outlet; 1-1-6. Three-phase output interface, 1-4-1, power module, 1-4-2, heat sink, 1-4-3, magnetic ring assembly, 1-4-4, film capacitor, 1-4-5, control board, 1-4-6, three-phase plastic-coated bracket, 1-4-7, drive board, 1-5-1, top arc surface of the cover, 1-5-2, internal reinforcing rib of the cover, 1-6-1, three-phase electrode plate, 1-6-2, electrode plate support, 1-6-3, current sensor, 1-6-4, three-phase output electrode plate, 1-6-5, three-phase terminal block. Detailed Implementation

[0030] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. These embodiments are based on the technical solution of the present invention and provide detailed implementation methods and specific operating procedures. However, the scope of protection of the present invention is not limited to the following embodiments.

[0031] Example

[0032] like Figure 1 As shown, this application proposes a high-power integrated electric drive system for electric vehicles, including a motor controller 1, a motor 2, and a reduction gearbox 3. The right end face of the reduction gearbox 3 is bolted to the left end face of the motor 2 housing, and internally connected to the motor rotor via a hollow shaft with internal splines to achieve power transmission. The motor controller 1 is mainly fixed to the motor 2 and the reduction gearbox 3 by four feet, with the two left feet fixed to two protruding columns on the top of the reduction gearbox 3, and the two right feet fixed to the top surface of the right end cover of the motor 2.

[0033] like Figure 2 As shown, a high-power motor controller for electric vehicles includes a housing 1-1. Inside the housing 1-1 are a busbar plate 1-3, an integrated control device 1-4, and a three-phase output device 1-6. The housing 1-1 is equipped with a two-phase connector 1-8, a low-voltage connector 1-7, a breather cover 1-2, a water inlet pipe 1-9, and a water outlet pipe. The water inlet pipe 1-9 is connected to the water inlet of the radiator 1-4-2, and one end of the water outlet pipe is connected to the water outlet of the radiator 1-4-2, while the other end is connected to the water inlet of the motor housing 2.

[0034] As shown in Figure 3 the box 1-1 and other parts of the mechanical interface includes low voltage plug-in interface 1-1-1, two-phase plug-in interface 1-1-2, water inlet hole 1-1-3, water outlet hole 1-1-5, respirator interface 1-1-4, three-phase output interface 1-1-6. Two-phase plug-in interface 1-1-2, low voltage plug-in interface 1-1-1 is located in the front side of the box 1-1. The water inlet pipe 1-9 is connected with the water inlet hole 1-1-3 located in the left side of the box 1-1 bottom, and leads to the inside bottom left side of the box 1-1, and communicates with the water inlet of the radiator 1-4-2. The water outlet hole 1-1-5 of the box 1-1 is located in the right side of the inside bottom of the box 1-1, one end surface communicates with the water outlet of the radiator 1-4-2, and the other end surface communicates with the water inlet of the motor 2 shell. The mating surface of the above three communication places is respectively installed with O-ring, realizing the water channel sealing between the water inlet hole 1-1-3, the water outlet hole 1-1-5 and the radiator 1-4-2, and the water channel sealing between the motor controller 1 and the motor 2. The respirator interface 1-1-4 is located in the left side of the box 1-1, and cooperates with the respirator cover 1-2. The three-phase output end is located in the right part of the box 1-1, used for fixing the three-phase terminal block 1-6-5, and leading out the three-phase output plate 1-6-4.

[0035] As shown in Figure 4 the integrated control device 1-4 includes power module 1-4-1, radiator 1-4-2, magnetic ring assembly 1-4-3, thin film capacitor 1-4-4, control board 1-4-5, three-phase plastic bracket 1-4-6, drive board 1-4-7. The power module 1-4-1 is fixed in the cavity of the radiator 1-4-2, and the power module 1-4-1 is provided with a plurality of double-layer arrangement in the radiator 1-4-2. The rib on the inner surface of the cavity is used to press the power module 1-4-1, and the power module 1-4-1 is tightly attached to one side of the radiator 1-4-2. When the power module 1-4-1 works, most of the heat is transferred to the radiator 1-4-2 through the heat dissipation surface. The cooling liquid flows into the radiator 1-4-2 from the water inlet pipe 1-9, and enters the radiator 1-4-2 through the water inlet hole 1-1-3, and carries away the heat on the radiator 1-4-2, and flows out into the motor 2 shell.

[0036] The control board 1-4-5 and the three-phase plastic support 1-4-6 are arranged on the top surface and one side of the long edge of the heat sink 1-4-2, respectively, the film capacitor 1-4-4 is arranged on the other side of the long edge of the heat sink 1-4-2, and the drive board 1-4-7 is vertically fixed on the three-phase plastic support 1-4-6 and is electrically connected with the signal line terminals of the three modules and the control board 1-4-5. The three-phase output end of the power module 1-4-1 is electrically connected with the input end of the three-phase plastic support 1-4-6, the signal output end of the power module 1-4-1 is electrically connected with the drive board 1-4-7, and the magnetic ring assembly 1-4-3 is sleeved on the input end of the film capacitor 1-4-4 and is fixed on the bottom surface of the box body 1-1.

[0037] The busbar pole plate 1-3 includes two pole plates and insulating paper covering the surfaces of the pole plates, is L-shaped as a whole and is arranged on the outer side of the integrated control device 1-4, one end of the busbar pole plate 1-3 is located at one end of the L-shape and is electrically connected with the two-phase plug-in 1-8, and the other end of the busbar pole plate 1-3 is located at the other end of the L-shape and is electrically connected with the input end of the integrated control device 1-4.

[0038] The input end of the film capacitor 1-4-4 is in the positive and negative busbar structure, the positive and negative busbars are electrically connected with the output end of the busbar copper bar after passing through the magnetic ring support hole, and the two are fixed on the threaded hole of the magnetic ring support. The output end of the film capacitor 1-4-4 is in the structure of three pairs of positive and negative busbars, and each pair of positive and negative busbars is electrically connected with the direct current input end of one power module 1-4-1.

[0039] As shown in Figure 5 The three-phase output device 1-6 includes a three-phase pole plate 1-6-1, a pole plate support 1-6-2, a current sensor 1-6-3, a three-phase output pole plate 1-6-4 and a three-phase terminal block 1-6-5. One end of the three-phase pole plate 1-6-1 is connected with the three-phase output end of the three-phase plastic support 1-4-6, the other end of the three-phase pole plate 1-6-1 is fixed on the pole plate support 1-6-2 and is electrically connected with one end of the three-phase output pole plate 1-6-4, the other end of the three-phase output pole plate 1-6-4 passes through the current sensor 1-6-3 and the three-phase terminal block 1-6-5 in sequence and then extends into the motor 2 to be fixed on the three-phase terminal block 1-6-5 together with the three-phase cable of the motor 2.

[0040] The top of the box body 1-1 is provided with a box cover 1-5, as shown in Figure 6 The top surface of the box cover 1-5 includes a rectangular plane in the center, and a warning sign can be pasted on the rectangular plane. Four circular arc surfaces are extended outward from the four edges of the rectangular plane, so that the box cover 1-5 has a shape of being high in the middle and low at the four corners. Figure 7 As shown in

[0041] The assembly process of the motor controller 1 is as follows:

[0042] 1, install three power modules 1-4-1 on the radiator 1-4-2. During installation, install the power module 1-4-1 in front of the cavity of the radiator 1-4-2, so that the heat dissipation surface of the power module 1-4-1 is opposite to one side of the heat dissipation channel of the radiator 1-4-2, and force it to slide backward along the cavity perpendicular to the cross-sectional direction of the power module 1-4-1 until only the terminal of the power module 1-4-1 is exposed outside the cavity. After installation, ensure that the power module 1-4-1 is tightly clamped inside the cavity without loosening, and that the heat dissipation surface of the power module 1-4-1 is tightly attached to the inner surface of the cavity.

[0043] 2, press the water inlet pipe 1-9 on the side of the box 1-1, and fix the low-voltage plug-in 1-7 on the side of the box 1-1 by screws.

[0044] 3, pass the input end of the film capacitor 1-4-4 through the magnetic ring support with a magnetic ring, and place the busbar plate 1-3 output end and the input end of the film capacitor 1-4-4 in a stack, and fix them on the magnetic ring support by bolts.

[0045] 4, place the output end of the film capacitor 1-4-4 and the input end of the power module 1-4-1 in a stack, and ensure that the two end faces are aligned, and weld them together by laser welding.

[0046] 5, place the output end of the power module 1-4-1 and the input end of the three-phase plastic bracket 1-4-6 in a stack, and ensure that the two side end faces are aligned, and fix the three-phase plastic bracket 1-4-6 on the front of the radiator 1-4-2 by screws, and weld the output end of the power module 1-4-1 and the input end of the three-phase plastic bracket 1-4-6 together by laser welding.

[0047] 6, fix the drive board 1-4-7 on the front of the three-phase plastic bracket 1-4-6 by bolts, and weld the signal pins of the power module 1-4-1 on the drive board 1-4-7 at the corresponding positions by wave soldering.

[0048] 7, fix the control board 1-4-5 on the upper surface of the radiator 1-4-2, and realize electrical connection between the control board 1-4-5 and the drive board 1-4-7 through the wire harness.

[0049] 8, place each plate of the three-phase output plate 1-6-4 into the wire slot of the three-phase terminal block 1-6-5, and fix it in the wire slot by screws.

[0050] 9. Pass one end of the three-phase output plate 1-6-4 through the current sensor 1-6-3, and stack it with one end of the three-phase plate 1-6-1. Then, fix it to the plate support 1-6-2 with screws. Fix the other end of the three-phase plate 1-6-1 to the output end of the three-phase plastic-coated bracket 1-4-6 with screws. At this point, all components inside the housing 1-1 are connected into a whole.

[0051] 10. Install the two O-rings into the annular grooves at the water inlet 1-1-3 and water outlet 1-1-5 inside the housing 1-1, respectively. Place the assembled components into the housing 1-1 and secure them with screws. Perform an airtightness test on the water channel; only proceed to the next step after the test is passed.

[0052] 11. Fix the input terminal of bus plate 1-3 to two-phase plug-in 1-8 with screws, and fix two-phase plug-in 1-8 to the front side of the enclosure 1-1 with screws.

[0053] 12. Perform an insulation withstand voltage test on motor controller 1.

[0054] 13. Secure the lid 1-5 to the top of the body 1-1 using screws.

[0055] 14. Block the water outlet of motor controller 1 and perform an airtightness test on motor controller 1. The installation of motor controller 1 is now complete.

[0056] The assembly of the integrated electric drive system will proceed as follows:

[0057] 15. First, connect the right end face of the gearbox 3 to the left end face of the motor 2 housing with bolts. The inside is connected to the motor rotor through a hollow shaft with internal splines.

[0058] 16. Install an O-ring at the water inlet of motor 2, align the water outlet of motor controller 1 with the water inlet of motor 2, and secure them with two screws.

[0059] 17. Fix the two left legs of the motor controller 1 to the two protruding columns on the top of the gearbox 3, and fix the two right legs to the top surface of the right end cover of the motor 2 to complete the assembly of the electric drive system.

[0060] 18. Finally, the entire electric drive system assembly was subjected to water channel air tightness and insulation withstand voltage tests.

Claims

1. A high-power motor controller for electric vehicles, comprising a box (1-1), a bus pole plate (1-3), an integrated control device (1-4), and a three-phase output device (1-6) are arranged in the box (1-1), characterized in that, The integrated control device (1-4) comprises a power module (1-4-1), a radiator (1-4-2), a magnetic ring assembly (1-4-3), a thin film capacitor (1-4-4), a control board (1-4-5), a three-phase plastic support (1-4-6), a drive board (1-4-7), the power module (1-4-1) is fixed in the cavity of the radiator (1-4-2), the control board (1-4-5) and the three-phase plastic support (1-4-6) are arranged on the top surface and one side of the long side of the radiator (1-4-2) respectively, the thin film capacitor (1-4-4) is arranged on the other side of the long side of the radiator (1-4-2), the drive board (1-4-7) is vertically fixed on the three-phase plastic support (1-4-6), the three-phase output end of the power module (1-4-1) is electrically connected with the input end of the three-phase plastic support (1-4-6), the signal output end of the power module (1-4-1) is electrically connected with the drive board (1-4-7), the magnetic ring assembly (1-4-3) is sleeved on the input end of the thin film capacitor (1-4-4) and fixed on the bottom surface of the box body (1-1); the bus pole plate (1-3) is L-shaped as a whole and arranged on the outer side of the integrated control device (1-4), one end of the bus pole plate (1-3) is located at one end of the L-shaped and electrically connected with the two-phase plug-in component (1-8), the other end of the bus pole plate (1-3) is located at the other end of the L-shaped and electrically connected with the input end of the integrated control device (1-4); The power module (1-4-1) is provided with a plurality of power modules, which are arranged in a double-layer manner in the radiator (1-4-2), and the heat dissipation surface of the power module (1-4-1) is attached to one side of the heat dissipation waterway.

2. A high power electric motor controller for an electric vehicle as claimed in claim 1, wherein, The box body (1-1) is provided with a two-phase plug-in component (1-8), a low-voltage plug-in component (1-7), a respirator cover (1-2), a water inlet pipe (1-9) and a water outlet pipe, the water inlet pipe (1-9) is in communication with the water inlet of the radiator (1-4-2), one end of the water outlet pipe is in communication with the water outlet of the radiator (1-4-2), and the other end is in communication with the water inlet of the motor casing.

3. A high power electric motor controller for an electric vehicle as claimed in claim 2, wherein, The two-phase plug-in component (1-8) and the low-voltage plug-in component (1-7) are located on the front side of the box body (1-1), the respirator cover (1-2) is located on the left side of the box body (1-1), the water inlet pipe (1-9) is located at the bottom of the left side of the box body (1-1), and the water outlet pipe is located on the right side of the box body (1-1).

4. The high power motor controller for electric vehicles as claimed in claim 1 wherein, The three-phase output device (1-6) comprises a three-phase pole plate (1-6-1), a pole plate support (1-6-2), a current sensor (1-6-3), a three-phase output pole plate (1-6-4) and a three-phase terminal block (1-6-5); one end of the three-phase pole plate (1-6-1) is connected with a three-phase output end of a three-phase plastic support (1-4-6), and the other end is fixed on the pole plate support (1-6-2) and electrically connected with one end of the three-phase output pole plate (1-6-4); the other end of the three-phase output pole plate (1-6-4) passes through the current sensor (1-6-3) and the three-phase terminal block (1-6-5) in sequence and then extends into the motor (2) and is fixed on the three-phase terminal block (1-6-5) together with a three-phase cable of the motor (2).

5. The high power motor controller for electric vehicles as claimed in claim 2 wherein, The matching surfaces of the water inlet pipe (1-9) and the water outlet pipe are respectively provided with O-rings.

6. The high power motor controller for electric vehicles as claimed in claim 1 wherein, The top of the box body (1-1) is provided with a box cover (1-5), the top surface of the box cover (1-5) comprises a rectangular plane in the center, four circular arc surfaces are extended outward from the four edges of the rectangular plane, so that the box cover (1-5) has a structure of high in the middle and low at the four corners.

7. A high power integrated electric drive system for electric vehicles, comprising a motor controller (1), a motor (2), a reduction gearbox (3), characterized in that, The motor controller (1) is the high-power motor controller (1) for electric vehicles as claimed in any one of claims 1-6.

8. The high power integrated electric drive system for electric vehicles of claim 7, wherein, The right end surface of the speed reducer (3) is connected with the left end surface of the motor (2) shell through bolts, and the inside is connected with the motor rotor through a hollow shaft with internal splines to realize power transmission; the motor controller (1) is fixed on the motor (2) and the speed reducer (3) through the supporting legs.

9. The high power integrated electric drive system for electric vehicles of claim 7, wherein, The water outlet hole of the water channel of the motor controller (1) is communicated with the water inlet of the motor (2) shell.

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