Dual Motor Controller and Electric Drive System

Abstract

The present invention belongs to the field of controllers, and discloses a dual-motor controller and an electric drive system. The dual-motor controller includes: a box body (10); a first high-voltage area (101) and a second high-voltage area (102), which are respectively formed in the upper and lower parts of the inner cavity of the box body; and a low-voltage area (103), which is located in the lower part of the inner cavity of the box body and is arranged separately from the second high-voltage area (102); wherein, the first high-voltage area (101), the second high-voltage area (102) and the low-voltage area (103) are adjacent to each other in sequence. The first high-voltage area (101) houses a filter (20) and a DC-LINK capacitor (40), the second high-voltage area (102) houses a DCDC component (90), an IGBT assembly is housed between the first high-voltage area (101) and the second high-voltage area (102), and the low-voltage area (103) houses a master control board (120). The dual-motor controller of the present invention can effectively solve the problems of poor heat dissipation effect, large volume and weight, low power density, low integration degree, poor EMC effect, high cost, etc. of the existing controller.

Description

Technical Field

[0001] The present invention relates to the technical field of controllers, and particularly to a dual-motor controller and an electric drive system. Background Art

[0002] With the development of the new energy vehicle market, the motor and electric control industry has received high attention, and the technology of high-density electric drive systems has developed rapidly. At present, single-motor drive systems are restricted by factors such as vehicle endurance and battery life, are not easily accepted by consumers, and have disadvantages such as low vehicle efficiency, low endurance, and low cost performance. Relatively speaking, dual-motor drive systems have advantages such as high efficiency, small size, low weight, and high power density, so they have gradually become the mainstream direction of electric drive system design.

[0003] However, the traditional dual-motor drive system still has the following deficiencies:

[0004] 1) Basically, single-sided heat dissipation devices encapsulated by power device manufacturers are used, resulting in poor heat dissipation capacity and poor scalability of the drive system, and it is not easy to implement platform design;

[0005] 2) The dual-motor drive solution only mechanically assembles two controllers and two motors together, or uses two sets of controller parts in one box. Therefore, it has a large volume and weight, low power density, high cost, and uses the same water circuit to cool two power devices, making the heat dissipation effect even worse;

[0006] 3) The electric drive system is not deeply integrated, resulting in complex control, increased connectors, more wiring harnesses, large volume, and high cost;

[0007] 4) The EMC (electromagnetic compatibility) performance of the electric drive system is poor, and it is easy to be interfered with or interfere with other components.

[0008] Therefore, at present, there is an urgent need for a power module with good heat dissipation performance and strong scalability, as well as an integrated design to reduce the weight and volume of the dual-motor drive system, improve the power density, and be able to implement platform design and reduce costs. At the same time, with the deep integration of the electric drive system, multi-in-one products also have great advantages in terms of volume, weight, and cost. Integrating components such as PDU (power distribution unit), DCDC (DC converter), and OBC (on-board charger) into the electric drive system also poses higher requirements for heat dissipation design, EMC design, and sealing design. Summary of the Invention

[0009] Aiming at at least one of the above defects or deficiencies in the prior art, the present invention provides a dual-motor controller and an electric drive system, which can effectively solve problems such as poor heat dissipation effect, large volume and weight, low power density, low integration degree, poor EMC effect, and high cost of the existing controller.

[0010] To achieve the above object, the present invention provides a dual-motor controller in a first aspect, the dual-motor controller comprising:

[0011] Box;

[0012] The first high-pressure area and the second high-pressure area are formed in the upper part and the lower part of the inner cavity of the box, respectively;

[0013] A low-pressure zone, located at the lower part of the inner cavity of the box body and isolated from the second high-pressure zone;

[0014] Among them, the first high-voltage area, the second high-voltage area and the low-voltage area are arranged adjacent to each other in sequence, the first high-voltage area accommodates a filter and a DC-LINK capacitor, the second high-voltage area accommodates a DCDC component, an IGBT assembly is accommodated between the first high-voltage area and the second high-voltage area, and the low-voltage area accommodates a main control board.

[0015] Optionally, the dual-motor controller includes a shielding top plate horizontally arranged in the lower part of the inner cavity of the box body, and the inner bottom wall of the box body is provided with a shielding side plate extending upward, and the shielding top plate, the shielding side plate, part of the box body bottom wall and part of the box body peripheral wall jointly define the low-pressure zone, and the second high-pressure zone and the low-pressure zone are isolated from each other by the shielding top plate and the shielding side plate.

[0016] Optionally, the dual-motor controller includes a box partition horizontally arranged in the inner cavity of the box to divide the first high-voltage area and the second high-voltage area, the box partition is formed with a partition through-groove, and the IGBT assembly is disposed in the partition through-groove.

[0017] Optionally, the filter and the DC-LINK capacitor are arranged in a spaced relationship along a lateral direction in the first high-voltage region.

[0018] Optionally, the dual-motor controller includes a DC connector and a PDU component, the output end of the DC connector is respectively connected to the input end of the filter and the input end of the PDU component, the PDU component is located in the first high-voltage area, and the filter and the PDU component are arranged on both sides of the DC-LINK capacitor.

[0019] Optionally, the DC connector is arranged through the upper peripheral wall of the box body.

[0020] Optionally, the dual-motor controller includes a PDU component arranged in the first high-voltage area, and the PDU component includes:

[0021] Component housing;

[0022] A split busbar installed in the component housing;

[0023] A PTC connector and a CMP connector are respectively connected to the output end of the shunt busbar; and

[0024] A plurality of fuses are arranged on the positive loop between the PTC connector and the shunt busbar and on the positive loop between the CMP connector and the shunt busbar.

[0025] Optionally, the PTC connector and the CMP connector are respectively arranged to penetrate the upper peripheral wall of the box body.

[0026] Optionally, the box body includes a box top cover covering the top opening of the inner cavity of the box body, the box top cover is formed with a top cover through-groove arranged vertically opposite to the fuse, the box body also includes a fuse cover plate that detachably covers the top cover through-groove, the dual motor controller includes an open cover interlocking connector and an open cover interlocking wiring harness, the open cover interlocking connector includes a first plug-in terminal and a second plug-in terminal that can be plugged into and connected to each other, the first plug-in terminal is fixedly mounted on the fuse cover plate, the second plug-in terminal is fixedly mounted on the component housing, and the open cover interlocking wiring harness connects the second plug-in terminal and the main control board.

[0027] Optionally, the filter comprises:

[0028] The filter base comprises a cylindrical cover body, wherein the cylindrical cover body is provided with a cylindrical cover cavity and a first cover opening and a second cover opening located at two axial ends of the cylindrical cover cavity;

[0029] A filter busbar is inserted into the cylindrical cover cavity, wherein the input end of the filter busbar extends out of the first cover opening and the output end extends out of the second cover opening;

[0030] A filter board, disposed on the filter base and electrically connected to the filter busbar; and

[0031] The magnetic ring is integrally formed and axially butted with the end wall of the cylindrical cover body portion provided with the second cover opening, and the output end of the filter busbar extends out of the magnetic ring.

[0032] Optionally, the DC-LINK capacitor is an integrated capacitor integrating the TM terminal capacitor function and the GM terminal capacitor function and comprises a capacitor output busbar group having a plurality of busbars stacked thereon, and the capacitor output busbar group is electrically connected to the input terminal of the IGBT assembly.

[0033] Optionally, a plurality of Y capacitors are integrated and installed in the DC-LINK capacitor.

[0034] Optionally, the DCDC component includes a horizontally arranged circuit board, and an input filter circuit, a voltage transformation circuit, a rectification output circuit, a control circuit, and a backup power supply circuit integrally installed on the circuit board. The positive input terminal of the DCDC component is located in the input filter circuit, and the negative input terminal is located in the backup power supply circuit. The positive output terminal and the negative output terminal of the DCDC component are both located in the rectification output circuit. The input filter circuit, the voltage transformation circuit, and the rectification output circuit are electrically connected in sequence. The backup power supply circuit, the voltage transformation circuit, and the rectification output circuit are electrically connected in sequence.

[0035] Optionally, a box body heat dissipation structure is provided on the box body partition, and at least part of the board surface of the circuit board is in contact with the box body heat dissipation structure.

[0036] Optionally, the dual-motor controller includes a DCDC connector electrically connected to the DCDC component, and the DCDC connector penetrates through the lower peripheral wall of the box body.

[0037] Optionally, the dual-motor controller includes a cooling plate assembly integrally installed with the IGBT assembly. The IGBT assembly includes at least one IGBT layer group, and the IGBT layer group includes at least one IGBT unit. The cooling plate assembly includes a plurality of cooling plates arranged in parallel at intervals. The IGBT layer group is stacked between two adjacent cooling plates. The IGBT unit is plate-shaped, and two plate surfaces thereof are respectively in contact with the plate surfaces of two adjacent cooling plates.

[0038] Optionally, the dual-motor controller includes an output transfer module located in the second high-voltage area. The output transfer module includes an output transfer female busbar installed by fitting the plate surface of the cooling plate.

[0039] Optionally, the master control board is an integrated master control board integrating a master control circuit, a drive circuit, and a signal detection circuit.

[0040] Optionally, the dual-motor controller includes an external output module. The external output module includes a three-phase output busbar. A current sensor is integrally installed on the master control board. The input end of the three-phase output busbar passes through the current sensor and is electrically connected to the output end of the IGBT assembly. The output end of the three-phase output busbar passes out of the box body.

[0041] Optionally, the dual-motor controller includes a housing cooling flow channel disposed in the inner cavity of the housing. An outwardly protruding heat-conducting column is provided on the outer wall of the housing cooling flow channel. A heat-conducting column groove is formed on the end face of the outwardly protruding heat-conducting column. The signal detection circuit includes a temperature-sensing element. The end wall of the outwardly protruding heat-conducting column abuts against the board surface of the master control board. The temperature-sensing element is located in the heat-conducting column groove, and a heat-conducting medium is filled between the temperature-sensing element and the inner wall of the heat-conducting column groove.

[0042] In a second aspect of the present invention, an electric drive system is provided. The electric drive system includes a motor, a generator, and the above-mentioned dual-motor controller electrically connected to the motor and the generator respectively.

[0043] The present invention provides a practical, reliable, and efficient design idea and solution for the design of a dual-motor controller, which well supplements the application examples of the dual-motor controller applied to a dual-motor drive system, and improves the power density, integration degree, heat dissipation capacity, EMC effect, and sealing performance of the dual-motor controller and the dual-motor drive system.

[0044] For example, through the high-voltage and low-voltage partition isolation design in the inner cavity of the dual-motor controller, the interference between high-voltage and low-voltage components is reduced, making the overall volume of the controller smaller, the power density higher, and the EMC effect better. By integrally assembling the IGBT assembly and the cooling plate assembly, double-sided heat dissipation of each IGBT unit is achieved, and the other components that need heat dissipation are concentrated and arranged close to the water channel, obtaining a shorter heat dissipation path, improving the heat dissipation effect. At the same time, the IGBT assembly and the cooling plate assembly adopt a platform design, and the number of cooling plates and IGBT units can be increased or decreased according to different power requirements, with strong scalability and product compatibility achieved. By integrating the PDU component and the DCDC component, the dual-motor controller can be matched and connected with the motor and the generator, reducing the use of connectors and high-voltage wire harnesses, reducing costs, and increasing the power density. By designing an integrated DC-LINK capacitor, the number of capacitors is saved, the volume and weight are reduced, the power density is increased, and the cost is reduced. By designing an integrated PCBA (printed circuit board assembly), such as the DCDC component and the master control board, the volume is reduced, the materials are reduced, the power density is increased, and the cost is reduced.

[0045] Other features and advantages of the present invention will be described in detail in the subsequent specific implementation section. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] The drawings are used to provide a further understanding of the present invention and constitute a part of the specification. They are used together with the following specific implementation to explain the present invention, but do not constitute a limitation to the present invention. In the drawings:

[0047] Figure 1Exploded view of the structure of a dual-motor controller in a specific embodiment of the present invention;

[0048] Figure 2 Schematic diagram of the structure of a PDU component in a specific embodiment of the present invention;

[0049] Figure 3 Schematic diagram of the structure of a filter in a specific embodiment of the present invention;

[0050] Figure 4 Exploded view of the structure of a DC-LINK capacitor, an input transfer module, and a double-sided cooling component in a specific embodiment of the present invention;

[0051] Figure 5 is Figure 4 exploded view of the double-sided cooling component in;

[0052] Figure 6 Exploded view of the structure of an output transfer module and a double-sided cooling component in a specific embodiment of the present invention;

[0053] Figure 7 Schematic diagram of the structure of a DCDC component in a specific embodiment of the present invention;

[0054] Figure 8 Used to show a water channel cover plate, a heat dissipation boss, and a crimping part in a specific embodiment of the present invention;

[0055] Figure 9 Schematic diagram of the structure of a main control board in a specific embodiment of the present invention;

[0056] Figure 10 High and low voltage partition schematic diagram of a dual-motor controller in a specific embodiment of the present invention;

[0057] Figure 11 Used to show an outward convex heat conducting column in a specific embodiment of the present invention;

[0058] Figure 12 Assembly drawing of a main control board and an outward convex heat conducting column in a specific embodiment of the present invention;

[0059] Figure 13 Assembly drawing of a main control board, an external output module, and a transfer output module in a specific embodiment of the present invention;

[0060] Figure 14 Circuit structure diagram of a dual-motor controller in a specific embodiment of the present invention.

[0061] Explanation of reference numerals:

[0062] 10 Box body

[0063] 101 First high-pressure area 102 Second high-pressure area

[0064] 103 Low-pressure area 104 Shielding top plate

[0065] 105 Shielding side plate 106 Box partition

[0066] 107 Water channel cover plate 108 Heat dissipation boss

[0067] 109 Outer convex heat conduction column 1010 Heat conduction column groove

[0068] 1011 Box top cover 1012 Top cover through groove

[0069] 1013 Fuse cover plate 1014 Box bottom cover

[0070] 20 Filter

[0071] 201 Filter base 202 Cylindrical cover body part

[0072] 203 Filter busbar 204 Positive busbar welding post

[0073] 205 Negative busbar welding post 206 Filter board

[0074] 207 Positive welding hole 208 Negative welding hole

[0075] 209 Grounding hole 2010 Ferrite core

[0076] 30 PDU assembly

[0077] 301 Assembly housing 302 Shunt busbar

[0078] 303 Shunt busbar input end 304 PTC connector

[0079] 305 CMP connector 306 Fuse

[0080] 307 Second plug-in terminal

[0081] 40 DC-LINK capacitor

[0082] 401 Capacitor output busbar group 402 Capacitor busbar connection hole

[0083] 50 Input transfer module

[0084] 501 Insulating strip board 502 Nut

[0085] 60 DC connector

[0086] 70 First plug-in terminal

[0087] 80 Breather valve

[0088] 90 DCDC component

[0089] 901 Circuit board 902 Input filter circuit

[0090] 903 Voltage transformation circuit 904 Rectification output circuit

[0091] 905 Control circuit 906 Backup power supply circuit

[0092] 908 MOS tube 909 Busbar

[0093] 9010 DCDC connector 9011 DCDC output busbar

[0094] 9012 DCDC power supply harness 9013 DCDC control power supply harness

[0095] 9014 DCDC control harness 9015 Backup power supply harness

[0096] 100 Crimping part

[0097] 110 Output transfer module

[0098] 120 Main control board

[0099] 1201 Main control circuit 1202 Drive circuit

[0100] 1203 Signal detection circuit 1204 Current sensor

[0101] 1205 Temperature sensing element

[0102] 130 External output module

[0103] 1301 Three-phase output busbar

[0104] 140 Resolver harness

[0105] 150 Double-sided cooling component

[0106] 1501 IGBT unit 1502 IGBT input terminal

[0107] 1503 IGBT input connection hole 1504 Cooling plate

[0108] 1505 Channel entrance 1506 External fluid entrance

[0109] 1507 Sealing ring

[0110] 160 Open cover interlock harness

[0111] 170 Fluid pipeline assembly Specific embodiments

[0112] The following will describe in detail the specific embodiments of the present invention with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are only for the purpose of illustrating and explaining the present invention, and are not intended to limit the present invention.

[0113] The following describes a dual-motor controller and an electric drive system according to the present invention with reference to the accompanying drawings.

[0114] As Figures 1 to 14 shown, the first exemplary embodiment of the present invention provides a dual-motor controller, which includes a box body 10 and controller functional components installed in the inner cavity of the box body. Specifically, a first high-voltage area 101 is formed in the upper part of the inner cavity of the box body, and a second high-voltage area 102 and a low-voltage area 103 which are isolated from each other are formed in the lower part of the inner cavity of the box body, and the first high-voltage area 101, the second high-voltage area 102 and the low-voltage area 103 are adjacent to each other in sequence, so that the low-voltage area 103 does not interfere with the two high-voltage areas.

[0115] The controller functional components mainly include a filter 20, a DC-LINK capacitor 40 (i.e., a DC support capacitor), a DCDC component 90 (i.e., a DC converter component), an IGBT assembly (i.e., an insulated gate Bipolar transistor assembly) and a main control board 120. Among them, the filter 20, the DC-LINK capacitor 40, the DCDC component 90 and the IGBT assembly are all components that work under high voltage, and the main control board 120 is a component that works under low voltage.

[0116] It should be mentioned first here, Figure 14 shows a circuit structure of the dual-motor controller of this exemplary embodiment. It can be seen that in addition to the functional components mentioned above, other functional components that implement different functions can be added to the dual-motor controller. There will be embodiments of other functional components in the following text. Combining with this circuit structure diagram is more convenient for understanding the electrical connection relationship between the functional components, and is also more convenient for understanding the considerations of the R & D personnel of this product when determining the layout method of the functional components.

[0117] In this exemplary embodiment, the filter 20 and the DC-LINK capacitor 40 are installed in the first high-voltage area 101, the DCDC component 90 is installed in the second high-voltage area 102, the IGBT assembly is installed between the first high-voltage area 101 and the second high-voltage area 102 (that is, part of the IGBT assembly is located in the first high-voltage area 101 and part is located in the second high-voltage area 102), and the main control board 120 is installed in the low-voltage area 103.

[0118] By performing a high-voltage and low-voltage partition isolation design in the inner cavity of the dual-motor controller, the interference between high-voltage and low-voltage components can be effectively reduced, making the overall volume of the controller smaller, the power density higher, and the EMC effect better.

[0119] There is no limit to the way of implementing the above high-voltage and low-voltage partition. Several embodiments are listed below for clearer illustration.

[0120] In one embodiment, referring to Figure 10 , the dual-motor controller includes a shielding top plate 104 horizontally arranged at the lower part of the inner cavity of the box body, and a shielding side plate 105 protruding upward is provided on the inner bottom wall of the box body 10. The low-voltage area 103 is jointly defined by the shielding top plate 104, the shielding side plate 105, part of the box body bottom wall and part of the box body peripheral wall. The shielding top plate 104 and the shielding side plate 105 jointly play a role in isolating the second high-voltage area 102 and the low-voltage area 103 from each other, and the shielding effect of the box body shell wall is fully utilized, making the overall volume of the controller small, the power density high, and the EMC effect good. If the structure is further simplified, the fixed installation point of the total control board 120 can also be set on the shielding top plate 104.

[0121] In one embodiment, continuing to refer to Figure 10 , the dual-motor controller includes a box body partition 106 horizontally arranged in the inner cavity of the box body. At this time, a first high-voltage area 101 is formed in the area above the box body partition 106 in the inner cavity of the box body, and a second high-voltage area 102 and a low-voltage area 103 are formed in the area below the box body partition 106. The box body partition 106 has a shielding effect and can effectively reduce the interference between the components in the two high-voltage areas. In addition, since the IGBT assembly is installed between the first high-voltage area 101 and the second high-voltage area 102, a partition through groove can be formed on the box body partition 106 for the IGBT assembly to pass through, so that the upper part of the IGBT assembly extends into the first high-voltage area 101 and the lower part extends into the second high-voltage area 102. And referring to the circuit structure shown in Figure 14 , there may be a need to connect the components in the first high-voltage area 101 to the components in the second high-voltage area 102 or the low-voltage area 103 through a conductive wire harness. Therefore, a wire harness through hole can be formed on the box body partition 106 for the conductive wire harness to pass through to achieve the corresponding electrical connection or signal transmission.

[0122] Generally, in order to adapt to the installation in a vehicle, the box body 10 of the dual-motor controller is set to have a vertical dimension smaller than the horizontal dimension. Therefore, when arranging multiple components in the same area, they should be arranged horizontally as much as possible. For example, the filter 20 and the DC-LINK capacitor 40 located in the first high-voltage area 101 are arranged horizontally at intervals.

[0123] When the dual-motor controller further includes a PDU component 30 (i.e., a power distribution unit component), since the output ends of the DC connectors in the dual-motor controller are respectively connected to the input end of the filter 20 and the input end of the PDU component 30, in order to save conductive wire harnesses or the length of the wire harness, it is preferable to arrange the DC connectors, the filter 20, and the PDU component 30 adjacently. Under this layout concept, the PDU component 30 is installed in the first high-voltage area 101, and the filter 20 and the PDU component 30 are arranged on the transverse sides of the DC-LINK capacitor 40, that is, the filter 20 and the PDU component 30 are in the same column on one side of the transverse direction, and the DC-LINK capacitor 40 is arranged on the other side of the transverse direction.

[0124] As for the DC connector 60, it is used to connect between the high-voltage power battery located outside the dual-motor controller and the input end of the filter 20. Therefore, the DC connector 60 is arranged through the upper peripheral wall of the box body 10, and a sealed connection is preferably formed between the DC connector 60 and the upper peripheral wall of the box body 10. In this way, it can not only realize its function of connecting the dual-motor controller and the high-voltage power battery, but also make it close to the filter 20 and the PDU component 30.

[0125] The specific components in the PDU component can be adjusted according to actual needs. For the dual-motor controller in this exemplary embodiment, it is usually required to be electrically connected to the vehicle ventilation system, such as being electrically connected to an air-conditioning compressor (abbreviation: "CMP") and an electric heater (abbreviation: "PTC").

[0126] Based on the above requirements, referring to Figure 2 , the PDU component 30 may include a component housing 301 and a shunt busbar 302, a PTC connector 304, a CMP connector 305, and a plurality of fuses 306 integrally installed on the component housing 301.

[0127] Among them, the component housing 301 can be made by an injection molding process, and the shunt busbar 302 can be embedded in the component housing 301. The PTC connector 304 and the CMP connector 305 can be respectively connected to the output end of the shunt busbar 302 through conductive wire harnesses to achieve power distribution. The input end 303 of the shunt busbar (including the positive and negative poles) is used to connect the DC connector 60. This busbar transfer method can increase the impedance in the loop and reduce the output of the noise band in the current, meeting the EMC requirements of the whole machine. In addition, a plurality of fuses 306 are arranged on the positive pole circuits between the PTC connector 304 and the shunt busbar 302 and between the CMP connector 305 and the shunt busbar 302 to achieve overcurrent protection.

[0128] Due to the need to be connected to an electric heater and an air-conditioning compressor, the PTC connector 304 and the CMP connector 305 are arranged to penetrate the upper peripheral wall of the box body 10 respectively, and a sealing connection is preferably formed between the PTC connector 304 and the upper peripheral wall of the box body 10 and between the CMP connector 305 and the upper peripheral wall of the box body 10. The remaining structures in the PDU assembly are located in the first high-voltage area 101.

[0129] To facilitate the installation of components into the inner cavity of the box body, the top and bottom of the box body 10 are usually open, and the top opening and the bottom opening are respectively detachably covered by a box body top cover 1011 and a box body bottom cover 1014. However, when it is necessary to observe the fuse 306, it is too cumbersome to directly remove the box body top cover 1011. For this reason, a top cover through groove 1012 vertically aligned with the fuse 306 can be formed on the box body top cover 1011, and a fuse cover plate 1013 detachably covering the top cover through groove 1012 is provided. When the fuse cover plate 1013 is removed, the fuse 306 can be directly observed for inspection or replacement.

[0130] For safety considerations, an open cover interlock connector can be provided in the dual-motor controller. Specifically, the open cover interlock connector includes a first plug-in terminal 70 and a second plug-in terminal 307 that can be plugged into each other and conduct electricity. The first plug-in terminal 70 is fixedly installed on the fuse cover plate 1013, the second plug-in terminal 307 is fixedly installed on the component housing 301, and the second plug-in terminal 307 and the master control board 120 are connected by an open cover interlock wiring harness 160. In this way, when the operator removes the fuse cover plate 1013, the first plug-in terminal 70 is disengaged from the second plug-in terminal 307, and the open cover interlock connector is immediately powered off. The master control board 120 immediately controls a series of actions when the open cover interlock connector is powered off to prevent the operator from getting an electric shock, thereby realizing the open cover protection function.

[0131] Refer to Figure 3 , the filter 20 of the present exemplary embodiment has a novel structure, which mainly includes a filter base 201, a filter busbar 203, a filter board 206, and a magnetic ring 2010.

[0132] Among them, the filter base 201 can be manufactured by an injection molding process. It includes a cylindrical cover body part 202, and the cylindrical cover body part 202 is provided with a cylindrical cover cavity and a first cover opening and a second cover opening at both axial ends of the cylindrical cover cavity. The filter busbar 203 is arranged in the cylindrical cover cavity, the input end of the filter busbar 203 extends out of the first cover opening and the output end extends out of the second cover opening. A positive busbar welding post 204 and a negative busbar welding post 205 are provided on the input end of the filter busbar 203. The filter plate 206 is arranged on the filter base 201, and the two can be fixedly connected by screws. The filter plate 206 is provided with a positive welding hole 207 and a negative welding hole 208, which are respectively butt-welded with the positive busbar welding post 204 and the negative busbar welding post 205, so that the filter plate 206 and the filter busbar 203 form an electrical connection. In addition, a grounding hole 209 and filter safety capacitors are also provided on the filter plate 206. The filter safety capacitors are provided between the positive and negative poles of the filter plate 206, between the positive pole and the ground, and between the negative pole and the ground, and can filter out differential-mode interference and common-mode interference. The magnetic ring 2010 innovatively adopts an integrally formed structure, avoiding performance degradation caused by segmentation, having strong overall filtering ability and good EMC effect, and ensuring that the dual-motor controller and external devices do not interfere with each other. The magnetic ring 2010 is axially butted with the end wall of the cylindrical cover body part 202 provided with the second cover opening and can be fixed by potting glue. The output end of the filter busbar 203 extends out of the magnetic ring 2010 to be connected with the input end of the DC-LINK capacitor.

[0133] In a traditional dual-motor controller, since the controller is used to be externally connected to a motor (abbreviation "TM") and a generator (abbreviation "GM"), the capacitor connected between the filter and the IGBT module needs to include a TM terminal capacitor and a GM terminal capacitor.

[0134] Different from the prior art, in the dual-motor controller of the present exemplary embodiment, referring to Figure 4 and Figure 14 , there is only one DC-LINK capacitor 40 connected between the filter and the IGBT assembly. This is because the DC-LINK capacitor 40 is an integrated capacitor integrating the functions of the TM terminal capacitor and the GM terminal capacitor, and multiple Y capacitors can be further integrally installed inside it for filtering. It has a high integration degree, can reduce the volume and weight, improve the power density, save materials such as capacitors and bolts, is convenient for assembly, and reduces the cost.

[0135] In addition, the DC-LINK capacitor 40 includes a capacitor output busbar group 401 in which multiple busbars are stacked, and the capacitor output busbar group 401 is electrically connected to the input end of the IGBT assembly. The stacked capacitor output busbar group can greatly reduce the stray inductance, reduce the peak voltage when the IGBT assembly is powered on or off, so that it can withstand a higher voltage platform and achieve a higher output power.

[0136] Reference Figure 5 The dual-motor controller further includes a cooling plate assembly integrally installed with the IGBT assembly, that is, the IGBT assembly and the cooling plate assembly are integrally installed as a double-sided cooling component 150.

[0137] Among them, the IGBT assembly includes at least one IGBT layer group, the IGBT layer group includes at least one IGBT unit 1501, the cooling plate assembly includes a plurality of cooling plates 1504 arranged in parallel at intervals, and the plurality of water-cooled plates 1504 can be fixedly connected by bolts. An IGBT layer group is stacked between two adjacent cooling plates 1504. The IGBT unit 1501 is plate-shaped and two plate surfaces thereof respectively abut against the plate surfaces of two adjacent cooling plates 1504. With such a setting, double-sided heat dissipation of each IGBT unit can be realized, and the way of stacking the cooling plate 1504 and the IGBT layer group belongs to a platform design, and the number of cooling plates 1504 and IGBT units 1501 can be increased or decreased according to different power requirements, with strong scalability and product compatibility achieved. A heat-conducting medium, such as heat-conducting silicone grease, etc., can also be coated on the contact area between the IGBT unit and the plate surface of the cooling plate 1504 to further enhance the heat dissipation effect.

[0138] The cooling plate 1504 can be a flow-channel type cooling plate provided with a cooling fluid channel inside. The channel inlet 1505 and the channel outlet of the cooling fluid channel are formed on the outer wall of the cooling plate 1504. Through an external pipeline, the cooling fluid can flow into or out of the cooling fluid channel.

[0139] Furthermore, matching the stacked structure of the double-sided cooling component 150, the plurality of cooling fluid channels in the plurality of cooling plates 1504 can be respectively formed as branch channels. Specifically referring to the attached drawings, the channel inlet 1505 and the channel outlet are formed on the plate surface of the cooling plate 1504. Among the plurality of cooling plates 1504, along the stacking direction of the cooling plate 1504 and the IGBT layer group, the plurality of channel inlets 1505 are sequentially aligned and communicated, and the plurality of channel outlets are sequentially aligned and communicated. An external fluid inlet 1506 communicated with the channel inlet 1505 and an external fluid outlet communicated with the channel outlet are further formed on one of the cooling plates 1504, so that a plurality of branched cooling fluid channels are connected between the external fluid inlet 1506 and the external fluid outlet. In this structure, the cooling fluid introduced from the external fluid inlet 1506 is branched into the cooling fluid channels of each cooling plate 1504 through the mutually connected plurality of channel inlets 1505, and then converges to the external fluid outlet through the mutually connected plurality of channel outlets for centralized external discharge. While ensuring double-sided heat dissipation of the IGBT unit, the number of external pipelines to be connected is saved, the integration degree of the double-sided cooling component 150 is higher, which is beneficial to reducing the volume and weight of the dual-motor controller and reducing costs.

[0140] Since the connection between the two adjacent channel inlets 1505 and the two adjacent channel outlets is achieved by connecting part of the plate surfaces of two adjacent cooling plates 1504, in order to ensure the sealing of the flow channel, it is preferred that a sealing ring 1507 is provided between the two adjacent channel inlets 1505 that are connected in position and between the two adjacent channel outlets that are connected in position.

[0141] The stacked structure of the double-sided cooling assembly 150 can be further configured as a symmetrical stacked structure. Specifically referring to the accompanying drawings, the cooling plate 1504 includes an intermediate cooling plate and a plurality of outer cooling plates symmetrically arranged on both sides of the intermediate cooling plate. Among them, the outer cooling plate is integrally formed, that is, a cooling fluid channel is integrally formed. The intermediate cooling plate includes two cooling plate splicing units spliced ​​along the stacking direction of the cooling plate 1504 and the IGBT layer group. At this time, the cooling fluid channel of the intermediate cooling plate is formed by aligning and splicing the flow channel half grooves on the plate surface of the two cooling plate splicing units, and at the same time, an external fluid inlet 1506 and an external fluid outlet are spliced. The two cooling plate splicing units can be welded and fixed by a vacuum brazing process to achieve sealing of the flow channel.

[0142] Reference Figure 4 and Figure 5 In order to make the IGBT input terminal 1502 in the double-sided cooling assembly 150 match the capacitor output busbar group 401 connected to the DC-LINK capacitor 40, the cooling plate 1504 can be set as a rectangular plate. In this case, the IGBT layer group includes a plurality of IGBT units 1501 arranged in sequence along the plate length direction of the cooling plate 1504, and the IGBT input terminal 1502 of each IGBT unit 1501 extends out of the cooling plate 1504 on the same side along the plate width direction of the cooling plate 1504 and along the cooling plate 1504. They are arranged in sequence in the length direction of the board, and an IGBT input connection hole 1503 is formed at the IGBT input terminal 1502. The capacitor output busbar group 401 is penetrated by a plurality of capacitor busbar connection holes 402 aligned with the plurality of IGBT input connection holes 1503 along the busbar stacking direction. The aligned IGBT input connection holes 1503 and capacitor busbar connection holes 402 are connected by conductive connecting columns, so that the structural coordination and electrical connection between the capacitor output busbar group 401 and the IGBT input terminal 1502 can be achieved.

[0143] Furthermore, in order to ensure the fixed connection between the capacitor output busbar group 401 and the IGBT input terminal 1502, an input adapter module 50 may be provided between the cooling plate 1504 and the IGBT input terminal 1502. Figure 4, the input transfer module 50 includes a plurality of insulating strip plates 501 connected side by side. A plurality of nuts 502 are arranged on the insulating strip plates 501 in sequence along the plate length direction. The conductive connection posts are bolts and can be screwed tightly with the nuts 502. When assembling the double-sided cooling assembly 150 and the DC-LINK capacitor 40, the capacitor output busbar group 401, a plurality of IGBT input ends 1502, and the input transfer module 50 are stacked and connected in sequence, so that a plurality of IGBT input connection holes 1503 are respectively aligned with a plurality of nuts 502 and a plurality of capacitor busbar connection holes 402. Then, bolts (conductive connection posts) are sequentially passed through the aligned capacitor busbar connection holes 402, IGBT input connection holes 1503, and nuts 502, and are screwed tightly with the nuts 502, thereby realizing the fixed connection between the capacitor output busbar group 401 and the IGBT input ends 1502. In addition, the input transfer module 50 also functions to insulate and isolate the IGBT input ends 1502 and the water-cooling plate 1504. Moreover, the input transfer module 50 is preferably set as a symmetric structure. For example, the two insulating strip plates 501 in the figure can be shared, with a platform design to reduce costs.

[0144] In the dual-motor controller of the present exemplary embodiment, referring to Figure 6 and Figure 13 , an output transfer module 110 for transitional connection can be provided between the external output module 130 for connecting an external motor and a generator and the IGBT output end. The output transfer module 110 includes an output transfer busbar. The output transfer busbar generates a relatively large amount of heat when energized. Therefore, it can be mounted by fitting the plate surface of the cooling plate 1504, without the need to additionally provide a heat dissipation structure, with high integration, simplified structure, which is beneficial to reducing the volume and weight of the dual-motor controller and reducing costs. A heat-conducting medium, such as heat-conducting silicone grease, etc., can also be coated on the contact area between the output transfer busbar and the plate surface of the cooling plate 1504 to further enhance the heat dissipation effect.

[0145] Referring to Figure 7 and Figure 14 , the DCDC component 90 of the present exemplary embodiment adopts an integrated PCBA design, specifically including a horizontally arranged circuit board 901 and an input filter circuit 902, a voltage transformation circuit 903, a rectification output circuit 904, a control circuit 905, and a standby power supply circuit 906 integrally installed on the circuit board 901. Among them, the positive input end of the DCDC component 90 is located in the input filter circuit 902, the negative input end of the DCDC component 90 is located in the standby power supply circuit 906, and the positive output end and the negative output end of the DCDC component 90 are both located in the rectification output circuit 904. The input filter circuit 902, the voltage transformation circuit 903, and the rectification output circuit 904 are electrically connected in sequence, and the standby power supply circuit 906, the voltage transformation circuit 903, and the rectification output circuit 904 are electrically connected in sequence.

[0146] In a dual-motor controller, the connection point between the DCDC component 90 and the filter 20 and the DC-LINK capacitor 40 can be connected through the DCDC power supply harness 9012.

[0147] Among them, the positive output terminal of the DCDC power supply harness 9012 is connected to the positive input terminal of the DCDC component 90, so as to be electrically connected to the input filter circuit 902. The input filter circuit 902, the voltage transformation circuit 903, and the rectifier output circuit 904 are electrically connected in sequence, and can be connected to components outside the dual-motor controller through the positive output terminal of the DCDC component 90 located in the rectifier output circuit 904. For example, referring to Figure 14 , it can be connected to the battery of the vehicle to charge the battery.

[0148] The negative output terminal of the DCDC power supply harness 9012 is connected to the negative input terminal of the DCDC component 90, so as to be electrically connected to the backup power supply circuit 906. The backup power supply circuit 906, the voltage transformation circuit 903, and the rectifier output circuit 904 are electrically connected in sequence, and can be grounded through the negative output terminal of the DCDC component 90 located in the rectifier output circuit 904 (usually connected to the box body 10 to achieve grounding).

[0149] It can be seen that by integrally installing the input filter circuit 902, the voltage transformation circuit 903, the rectifier output circuit 904, the control circuit 905, and the backup power supply circuit 906 on the circuit board 901 of the DCDC component 90, while meeting the functions of the dual-motor controller, the use of connectors and high-voltage harnesses is reduced. That is, through this integrated PCBA design, the volume can be effectively reduced, the materials can be reduced, the power density can be increased, and the cost can be reduced.

[0150] The DCDC component 90 is preferably set with high-voltage and low-voltage partitions, that is, the circuit board 901 is divided into a high-voltage circuit area and a low-voltage circuit area. Among them, the backup power supply circuit 906, the input filter circuit 902, and the voltage transformation circuit 903 are integrally installed in the high-voltage circuit area, and the rectifier output circuit 904 and the control circuit 905 are integrally installed in the low-voltage circuit area, thereby improving the overall EMC effect.

[0151] Specifically, the shape structure of the circuit board 901 can be optimized to define the high-voltage circuit area and the low-voltage circuit area, so as to be easier to identify different circuit areas during production, processing, and use. For example, referring to the attached drawings, the circuit board 901 includes a first board body portion extending along a straight line and a second board body portion connected to the end of the first board body portion. The direction in which the second board body portion extends from the end of the first board body portion is not the straight-line extension direction of the first board body portion. Therefore, it is extremely easy to identify the positions of the high-voltage circuit area and the low-voltage circuit area from the appearance.

[0152] Further, in combination with the electrical connection sequence between multiple functional circuits, in the first board body portion, the voltage transformation circuit 903 is integrally installed at one end connected to the second board body portion, and the backup power supply circuit 906 is integrally installed at the other end, and the input filter circuit 902 is arranged between the backup power supply circuit 906 and the voltage transformation circuit 903. With such an arrangement, it can not only meet the requirements of high and low voltage zoning layout but also be conducive to simplifying the circuit layout on the circuit board.

[0153] In addition, the backup power supply circuit 906 is electrically connected to the master control board 120 through a backup power supply wire harness 9015. When the master control board 120 loses normal power supply, the energy stored in the DC-LINK capacitor 40 can be quickly released to the backup power supply circuit 906, that is, temporarily supply power to it, so as to temporarily supply power to the master control board 120, enabling the master control board 120 to perform emergency operations during this period. In other words, the function of the backup power supply circuit 906 is to enable the master control board 120 to still enter the safe mode after power failure, meeting the requirements of functional safety.

[0154] The control circuit 905 in the DCDC component 90 can be connected to the master control board 120 through a DCDC control power wire harness 9013 and a DCDC control signal wire harness 9014. Similar to the backup power supply wire harness 9015, the purpose is to achieve signal or current intercommunication.

[0155] In the case where a DCDC component is provided, in order to connect the positive output terminal of the DCDC component to a component outside the dual-motor controller, a DCDC connector 9010 also needs to be provided in the dual-motor controller. The DCDC connector 9010 can also be regarded as a component of the DCDC component 90, that is, as a part of the positive output terminal of the DCDC component 90. Considering integration and installation in the vicinity, the DCDC connector 9010 can be arranged to penetrate the lower peripheral wall of the box body 10, and a sealed connection is preferably formed between the DCDC connector 9010 and the lower peripheral wall of the box body 10. In addition, a DCDC output busbar 9011 connected to the input terminal of the DCDC connector 9010 is usually provided in the positive output terminal of the DCDC component 90.

[0156] Since multiple MOS transistors 908 (i.e., metal-oxide-semiconductor field-effect transistors) in the backup power supply circuit 906 and the voltage transformation circuit 903, as well as the busbar 909 in the rectifier output circuit 904 (which is part of the negative output terminal of the DCDC component) are all components with large heat generation, it is therefore preferred to dissipate heat specifically for the corresponding circuit areas.

[0157] In an alternative heat dissipation embodiment, a housing cooling channel is provided in the inner cavity of the housing. The housing cooling channel allows a cooling fluid to flow through. By bringing the portion of the circuit board 901 that needs to be specifically cooled into contact with the outer wall of the housing cooling channel, heat exchange can be carried out using the cooling fluid in the channel, thereby quickly removing heat and ensuring the heat dissipation effect.

[0158] When a housing partition 106 is provided in the dual-motor controller, the housing cooling channel can be arranged on the housing partition 106. Since the housing partition 106 is originally used to divide the first high-voltage area 101 and the second high-voltage area 102, and the DCDC component is located in the second high-voltage area 102, the heat dissipation path can be shortened, and the heat dissipation effect of the housing cooling channel can be improved.

[0159] In addition, increasing the thermal contact area is also beneficial to improving the heat dissipation effect. Referring to Figure 8 , a water channel cover plate 107 can be provided as part of the outer wall of the housing cooling channel. The water channel cover plate 107 can be set as a flat plate to fit the circuit board 901 of the DCDC component 90 with a larger area. The water channel cover plate 107 can be fixed by friction stir welding, and columnar PIN pins can be provided or a thermal conductive medium (such as thermal conductive silicone grease) can be coated between the contact surfaces of the circuit board 901 and the water channel cover plate 107 to further enhance the heat dissipation capacity.

[0160] A crimping member 100 can also be provided in the dual-motor controller to keep at least part of the surface of the circuit board 901 in contact with the outer wall of the housing cooling channel. Referring to Figure 8 , the crimping member 100 can be made of spring steel material. It includes a crimping member fixing part and a plurality of crimping member elastic legs that obliquely extend from the outer peripheral edge of the crimping member fixing part. Among them, the crimping member fixing part is fixedly connected to the inner wall of the housing 10, and the plurality of crimping member elastic legs jointly elastically crimp on the DCDC component 90 to press the circuit board 901 against the outer wall of the housing cooling channel. For example, the plurality of crimping member elastic legs can be respectively crimped on a plurality of MOS transistors 908 in the transformer circuit 903, so as to provide an additional pressing force for the circuit board 901, reduce the contact thermal resistance between the circuit board 901 and the housing cooling channel, and further enhance the heat dissipation capacity.

[0161] In another alternative heat dissipation embodiment, referring to Figure 8 , the dual-motor controller includes a heat dissipation boss 108 fixedly connected to the inner wall of the housing. By bringing the portion of the circuit board 901 that needs to be specifically cooled into contact with the tabletop of the heat dissipation boss 108, direct contact heat conduction can be achieved, the heat transfer path can be shortened, the heat dissipation effect can be improved, and the heat dissipation design difficulty can be reduced. For example, the heat dissipation boss 108 can also be arranged on the housing partition 106 and extend into the second high-voltage area 102, so as to be able to contact the circuit board 901.

[0162] Reference Figure 9 The main control board 120 of this exemplary embodiment can be innovatively set as an integrated main control board integrated with a main control circuit 1201, a drive circuit 1202, and a signal detection circuit 1203. That is, the functions of control, drive, and signal detection are integrated in a single main control board 120.

[0163] For example, with reference to Figure 1 and Figure 14 The PIN pins of the IGBT assembly can be electrically connected to the main control board 120 by welding to realize the control and drive functions of the IGBT assembly; a current sensor 1204 can be provided on the main control board 120 to enable the three-phase output busbar 1301 in the external output module 130 to pass through the current sensor 1204 to realize real-time current acquisition; the DCDC control power line harness 9013, the DCDC control line harness 9014, and the spare power line harness 9015 can be connected between the DCDC component 90 and the main control board 120 to realize signal and current intercommunication; the resolver harness 140 can be connected between the main control board 120 and the resolver of the motor (including the motor and the generator) to realize the feedback of the motor speed and the rotor angle; the PTC interlock harness can be connected between the PTC connector 304 and the main control board 120 to realize the corresponding interlock function.

[0164] Compared with the traditional dual-motor controller, the dual-motor controller of this exemplary embodiment reduces two drive boards, reduces the use of harnesses such as PWM harnesses, current detection harnesses, and temperature detection harnesses, has better anti-interference ability, good EMC effect, is convenient for material management, simplifies the assembly process, and reduces costs.

[0165] According to the foregoing, the three-phase output busbar 1301 in the external output module 130 can pass through the current sensor 1204 to realize real-time current acquisition. Specifically, with reference to Figure 13 The input end of the three-phase output busbar 1301 passes upward through the current sensor 1204 and is electrically connected to the output end of the IGBT assembly. If there is also an output transfer module 110, the input end of the three-phase output busbar 1301 is connected to the output end of the output transfer module 110, and the output end of the three-phase output busbar 1301 then passes out of the box body 10 for connection to the motor and the generator.

[0166] Since the output transfer module 110 serves as a transition connection module between the IGBT assembly and the external output module 130, the output transfer module 110 should also be arranged close to the IGBT assembly and the external output module 130 in terms of layout. Combining the foregoing, the output transfer module 110 can be mounted against the outer wall of the cooling plate 1504, and the lower part of the cooling plate 1504 should extend into the second high-voltage area 102 together with the IGBT assembly, and a part of the external output module 130 is located in the low-voltage area 103. Therefore, in order to install the output transfer module 110 close to the IGBT assembly and the external output module 130, it is preferable to arrange the output transfer module 110 in the second high-voltage area 102.

[0167] The external output module 130 can be manufactured by an injection molding process. The upward penetration of the input end of the three-phase output busbar 1301 through the current sensor 1204 also provides a tightening area for the connection between the output transfer module 110 and the external output module 130. In addition, the external output module 130 can be mounted on the bottom cover 1014 of the box by screws. A sealing groove can be provided in the contact area between the external output module 130 and the bottom cover 1014 of the box, so that a sealing ring can be placed in the sealing groove to achieve sealing. Furthermore, the external TM output end and the external GM output end of the external output module 130 adopt the same structural design, with platformized and modular design, which can reduce costs.

[0168] A resolver seal block can be provided on the resolver harness 140. The resolver seal block can be manufactured by a low-temperature injection molding process. One end of the resolver harness 140 passes through the bottom wall of the box, and a sealing groove is provided in the contact area with the bottom wall of the box. A resolver sealing ring is used for sealing, so as to ensure that the three-phase connection end between the dual-motor controller and the motor is completely sealed, reaching the sealing level of IP67&IP6K9K, isolating the motor from the dual-motor controller, and thus realizing the two-way working environmental protection.

[0169] Referring to Figure 11 and Figure 12 In order to timely obtain the temperature change information of the cooling fluid in the box cooling channel to judge the running condition of the whole vehicle, an outward convex heat conduction column 109 can be provided on the outer wall of the box cooling channel. A heat conduction column groove 1010 is formed on the end face of the outward convex heat conduction column 109. The signal detection circuit 1203 integrated in the master control board 120 has the function of a temperature detection circuit and includes a temperature sensing element 1205. Among them, the end wall of the outward convex heat conduction column 109 abuts against the board surface of the master control board 120, the temperature sensing element 1205 is located in the heat conduction column groove 1010, and a heat conduction medium is filled between the temperature sensing element 1205 and the inner wall of the groove of the heat conduction column groove 1010.

[0170] By setting temperature detection points on the cooling channels of the housing, the temperature change of the cooling fluid can be quickly detected, and the sampled data is accurate, avoiding sampling data deviation caused by poor contact or device damage caused by excessive stress and strain of the circuit board. In addition, the setting of the heat conduction column groove 1010 helps to prevent the overflow of the heat conduction medium.

[0171] In addition, the dual-motor controller of the present exemplary embodiment further includes a breather valve 80 and a fluid pipeline assembly 170 disposed on the outer wall of the housing 10. The breather valve 80 is used to balance the pressure inside and outside the housing. The fluid pipeline assembly 170 includes a fluid inlet pipe and a fluid outlet pipe. The fluid inlet pipe is used to introduce the cooling fluid into the cooling channels in the dual-motor controller, and the fluid outlet pipe is used to export the cooling fluid from the cooling channels out of the dual-motor controller. The cooling channels referred to herein may include the aforementioned housing cooling channels and the cooling fluid channels of the cooling plate 1504.

[0172] Next, in combination with the foregoing multiple embodiments related to the cooling channels, a heat dissipation embodiment with a complete cooling fluid circulation path is provided.

[0173] Specifically, the aforementioned housing cooling channels include an upstream section of the housing cooling channel connected to the downstream end of the fluid inlet pipe and a downstream section of the housing cooling channel connected to the upstream end of the fluid outlet pipe. The upstream section of the housing cooling channel is provided with an outwardly convex heat conduction column 109 as a temperature detection point. The downstream section of the housing cooling channel is provided with a water channel cover plate 107 and is in thermal contact with a partial board surface of the circuit board 901 of the DCDC component 90. The double-sided cooling component 150 formed by the integrated packaging of the IGBT assembly and the cooling plate assembly is connected between the upstream section and the downstream section of the housing cooling channel. Among them, the external fluid inlet 1506 of the double-sided cooling component 150 is connected to the downstream end of the upstream section of the housing cooling channel, and the external fluid outlet of the double-sided cooling component 150 is connected to the upstream end of the downstream section of the housing cooling channel.

[0174] Based on the above connection relationship, during cooling and heat dissipation, the cooling fluid is introduced from the fluid inlet pipe of the dual-motor controller, and then sequentially flows through the upstream section of the housing cooling channel and the external fluid inlet 1506 of the double-sided cooling component 150, and then is split into multiple cooling fluid channels in a plurality of cooling plates 1504, and then converges to the external fluid outlet of the double-sided cooling component 150, and finally sequentially flows through the downstream section of the housing cooling channel and the fluid outlet pipe to flow out of the dual-motor controller.

[0175] As Figure 14 shown, the second exemplary embodiment of the present invention provides an electric drive system, which includes a motor, a generator, and the above-mentioned dual-motor controller electrically connected to the motor and the generator respectively. Obviously, the electric drive system has all the technical effects brought by the dual-motor controller, and will not be repeated here.

[0176] This exemplary embodiment mainly provides a practical, reliable, and efficient design idea and solution for the design of a dual-motor controller, which well complements the application examples of the dual-motor controller applied to the dual-motor drive system, and improves the power density, integration, heat dissipation capacity, EMC effect, and sealing performance of the dual-motor controller and the dual-motor drive system.

[0177] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc. indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings. They are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus cannot be understood as a limitation of the present invention.

[0178] In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include at least one of such features. In the description of the present invention, the meaning of "a plurality" is at least two, such as two, three, etc., unless otherwise specifically and clearly defined.

[0179] In the present invention, unless otherwise clearly specified and limited, the terms "mounted", "connected", "connected to", "fixed", etc. should be understood in a broad sense. For example, it may be a fixed connection, a detachable connection, or integrated; it may be a mechanical connection, an electrical connection, or communicable with each other; it may be directly connected, or indirectly connected through an intermediate medium, and may be the internal communication of two elements or the interaction relationship between two elements, unless otherwise clearly limited. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0180] In the present invention, unless otherwise clearly specified and limited, the first feature being "on" or "under" the second feature may be that the first and second features are in direct contact, or the first and second features are indirectly in contact through an intermediate medium. Moreover, the first feature being "above", "over", and "on" the second feature may be that the first feature is directly above or obliquely above the second feature, or merely indicates that the first feature has a higher horizontal height than the second feature. The first feature being "under", "below", and "beneath" the second feature may be that the first feature is directly below or obliquely below the second feature, or merely indicates that the first feature has a lower horizontal height than the second feature.

[0181] In the description of this specification, the descriptions referring to terms such as "one embodiment", "some embodiments", "examples", "specific examples", or "some examples", etc., mean that the specific features, structures, materials, or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in a suitable manner in any one or more embodiments or examples. In addition, without contradiction, those skilled in the art can combine and combine the different embodiments or examples described in this specification and the features of different embodiments or examples.

[0182] Although the embodiments of the present invention have been shown and described above, it can be understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those of ordinary skill in the art can make changes, modifications, substitutions, and variations to the above embodiments within the scope of the present invention.

Claims

1. A dual-motor controller, characterized in that, The dual motor controller comprises: Box body (10); A first high-pressure area (101) and a second high-pressure area (102) are formed at the upper part and the lower part of the inner cavity of the casing, respectively; and A low-pressure zone (103) is located at the lower part of the inner cavity of the box body and is isolated from the second high-pressure zone (102); The first high-voltage area (101), the second high-voltage area (102) and the low-voltage area (103) are arranged adjacent to each other in sequence; the first high-voltage area (101) accommodates a filter (20) and a DC-LINK capacitor (40); the second high-voltage area (102) accommodates a DCDC component (90); an IGBT assembly is accommodated between the first high-voltage area (101) and the second high-voltage area (102); and the low-voltage area (103) accommodates a main control board (120); The dual-motor controller comprises a cooling plate assembly integrally mounted with the IGBT assembly, the IGBT assembly and the cooling plate assembly are integrally mounted as a double-sided cooling component (150), the IGBT assembly comprises at least one IGBT layer group, the IGBT layer group comprises at least one IGBT unit (1501), the cooling plate assembly comprises a plurality of cooling plates (1504) arranged in parallel and spaced apart, the IGBT layer group is stacked between two adjacent cooling plates (1504), the IGBT unit (1501) is in a plate shape and two plate surfaces respectively abut against plate surfaces of two adjacent cooling plates (1504); The cooling plate (1504) is a channel-type cooling plate having a cooling fluid channel therein, and a plurality of cooling fluid channels in a plurality of cooling plates (1504) are matched with the stacked structure of the double-sided cooling component (150) to form branch flow channels respectively, and the stacked structure of the double-sided cooling component (150) is a symmetrical stacked structure, and the cooling plate (1504) includes an intermediate cooling plate and a plurality of outer cooling plates symmetrically arranged on both sides of the intermediate cooling plate.

2. The dual-motor controller according to claim 1, characterized in that, The dual-motor controller comprises a shielding top plate (104) horizontally arranged at the lower part of the inner cavity of the box body, and the inner bottom wall of the box body (10) is provided with a shielding side plate (105) extending upward, and the shielding top plate (104), the shielding side plate (105), part of the box body bottom wall and part of the box body peripheral wall jointly define the low-pressure area (103), and the second high-pressure area (102) and the low-pressure area (103) are isolated from each other by the shielding top plate (104) and the shielding side plate (105).

3. The dual-motor controller according to claim 1, characterized in that, The dual-motor controller comprises a box partition (106) horizontally arranged in the inner cavity of the box to divide the first high-voltage area (101) and the second high-voltage area (102), the box partition (106) being formed with a partition through-groove, and the IGBT assembly is arranged in the partition through-groove.

4. The dual-motor controller according to claim 1, characterized in that, The filter (20) and the DC-LINK capacitor (40) are arranged in a spaced relationship along a lateral direction in the first high voltage region (101).

5. The dual-motor controller according to claim 4, characterized in that, The dual-motor controller includes a DC connector (60) and a PDU assembly (30). The output ends of the DC connector (60) are respectively connected to the input end of the filter (20) and the input end of the PDU assembly (30). The PDU assembly (30) is located in the first high-voltage area (101), and the filter (20) and the PDU assembly (30) are arranged on the transverse sides of the DC-LINK capacitor (40).

6. The dual-motor controller according to claim 5, characterized in that, The DC connector (60) penetrates through the upper peripheral wall of the box body (10).

7. The dual-motor controller according to claim 1, characterized in that, The dual-motor controller includes a PDU assembly (30) arranged in the first high-voltage area (101). The PDU assembly (30) includes: An assembly housing (301); A shunt busbar (302), installed in the assembly housing (301); A PTC connector (304) and a CMP connector (305), respectively connected to the output end of the shunt busbar (302); and a plurality of fuses (306), arranged on the positive pole circuits between the PTC connector (304) and the shunt busbar (302) and between the CMP connector (305) and the shunt busbar (302).

8. The dual-motor controller according to claim 7, characterized in that, The PTC connector (304) and the CMP connector (305) respectively penetrate through the upper peripheral wall of the box body (10).

9. The dual-motor controller according to claim 7, characterized in that, The box body (10) includes a box body top cover (1011) covering the top opening of the box body cavity. The box body top cover (1011) is formed with a top cover through groove (1012) axially aligned with the fuse (306). The box body (10) further includes a fuse cover plate (1013) detachably covering the top cover through groove (1012). The dual-motor controller includes an open cover interlock connector and an open cover interlock wire harness (160). The open cover interlock connector includes a first plug-in terminal (70) and a second plug-in terminal (307) that can be plugged into each other and conduct. The first plug-in terminal (70) is fixedly installed on the fuse cover plate (1013), and the second plug-in terminal (307) is fixedly installed on the assembly housing (301). The open cover interlock wire harness (160) connects the second plug-in terminal (307) and the main control board (120).

10. The dual-motor controller according to claim 1, characterized in that, The filter (20) includes: A filter base (201), including a cylindrical cover body part (202). The cylindrical cover body part (202) is provided with a cylindrical cover cavity and a first cover opening and a second cover opening at both axial ends of the cylindrical cover cavity; A filter busbar (203), passing through the cylindrical cover cavity. The input end of the filter busbar (203) extends out of the first cover opening and the output end extends out of the second cover opening; A filter board (206) is provided on the filter base (201) and is electrically connected to the filter bus bar (203); and a magnetic ring (2010) is integrally formed and axially docked with the end wall of the cylindrical cover body part (202) provided with the second cover opening, and the output end of the filter bus bar (203) extends out of the magnetic ring (2010).

11. The dual-motor controller according to claim 1, characterized in that, The DC-LINK capacitor (40) is an integrated capacitor integrating the functions of the TM terminal capacitor and the GM terminal capacitor and includes a capacitor output bus bar group (401) in which a plurality of bus bars are stacked, and the capacitor output bus bar group (401) is electrically connected to the input end of the IGBT assembly.

12. The dual-motor controller according to claim 11, characterized in that, A plurality of Y capacitors are integrally installed in the DC-LINK capacitor (40).

13. The dual-motor controller according to claim 3, characterized in that, The DCDC component (90) includes a horizontally arranged circuit board (901) and an input filter circuit (902), a voltage transformation circuit (903), a rectification output circuit (904), a control circuit (905) and a standby power supply circuit (906) integrally installed on the circuit board (901). The positive input end of the DCDC component (90) is located in the input filter circuit (902) and the negative input end is located in the standby power supply circuit (906). The positive output end and the negative output end of the DCDC component (90) are both located in the rectification output circuit (904). The input filter circuit (902), the voltage transformation circuit (903) and the rectification output circuit (904) are electrically connected in sequence, and the standby power supply circuit (906), the voltage transformation circuit (903) and the rectification output circuit (904) are electrically connected in sequence.

14. The dual-motor controller according to claim 13, characterized in that,A box body heat dissipation structure is provided on the box body partition board (106), and at least part of the board surface of the circuit board (901) abuts against the box body heat dissipation structure.

15. The dual-motor controller according to claim 1, wherein The dual-motor controller includes a DCDC connector (9010) electrically connected to the DCDC component (90), and the DCDC connector (9010) penetrates through the lower peripheral wall of the box body (10).

16. The dual-motor controller according to claim 1, wherein The dual-motor controller includes an output transfer module (110) located in the second high-voltage area (102), and the output transfer module (110) includes an output transfer bus bar installed by fitting the board surface of the cooling plate (1504).

17. The dual-motor controller according to claim 1, wherein The master control board (120) is an integrated master control board integrating a master control circuit (1201), a drive circuit (1202) and a signal detection circuit (1203).

18. The dual-motor controller according to claim 17, wherein The dual-motor controller includes an external output module (130), and the external output module (130) includes a three-phase output bus bar (1301). A current sensor (1204) is integrally installed on the master control board (120). The input end of the three-phase output bus bar (1301) passes through the current sensor (1204) and is electrically connected to the output end of the IGBT assembly, and the output end of the three-phase output bus bar (1301) penetrates out of the box body (10).

19. The dual-motor controller according to claim 17, wherein The dual-motor controller includes a box body cooling flow channel arranged in the inner cavity of the box body. An outwardly convex heat conducting column (109) is provided on the outer wall of the box body cooling flow channel. A heat conducting column groove (1010) is formed on the end face of the outwardly convex heat conducting column (109). The signal detection circuit (1203) includes a temperature sensing element (1205). The end wall of the outwardly convex heat conducting column (109) abuts against the plate surface of the master control board (120). The temperature sensing element (1205) is located in the heat conducting column groove (1010), and a heat conducting medium is filled between the temperature sensing element (1205) and the inner wall of the heat conducting column groove (1010).

20. An electric drive system, wherein The electric drive system includes an electric motor, a generator, and the dual-motor controller according to any one of claims 1 to 19, which is electrically connected to the electric motor and the generator respectively.

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