An integrated dual-drive system control device

Abstract

The present invention relates to a control device for an integrated dual-drive system, which includes a drive unit board, a power component, a shielding pressure plate, a Hall detector, an AC output copper plate, an output support, a thin-film capacitor, and a radiator. A long strip-shaped hollow groove is provided in the center of the radiator. The top surface of the thin-film capacitor is provided with copper row support feet. The thin-film capacitor is fixed on the lower bottom surface of the radiator, and the copper row support feet pass through the long strip-shaped hollow groove. There are two sets of power components, shielding pressure plates, output supports, AC output copper plates, and Hall detectors, and they are symmetrically arranged on both sides of the long strip-shaped hollow groove on the radiator. The drive unit board is installed above the shielding pressure plate and the power component. The two sides of the drive unit board are respectively fixedly connected to the root connection columns on the two sets of output supports, and the drive unit board is electrically connected to the signal pins of the power component. Compared with the prior art, the present invention has the advantages of high integration, compact structure, good assembly flexibility, and high maintainability.

Description

Technical Field

[0001] The present invention relates to the field of dual-drive systems for new energy vehicles, and more particularly to an integrated dual-drive system control device. Background Art

[0002] The motor controller used in traditional new energy vehicles is composed of IGBT (Insulated Gate Bipolar Transistor), film capacitors, Hall detectors, shielding plates, and control boards. Each unit is installed inside the motor controller box body through a stacked arrangement. Among them, there is a lack of a manufacturing and fixing relationship between the IGBT, film capacitors, drive boards, control boards, and shielding plates. Each part is independently assembled inside the controller box body, resulting in low space utilization efficiency of the controller box body, inconvenient assembly, and inconvenient maintenance and repair. Especially in the dual-motor drive control system, two sets of the same power modules need to be assembled, and the same heat dissipation system also needs to expand the area to dissipate heat for the two modules. This arrangement of separate power modules and heat dissipation water channels will cause the overall electrical device to be large in volume, low in integration, and the assembly process is cumbersome, making it difficult to meet the development requirements of current motor controller integration, miniaturization, and automated production. Summary of the Invention

[0003] The purpose of the present invention is to overcome the above-mentioned defects existing in the prior art and provide an integrated dual-drive system control device.

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

[0005] An integrated dual-drive system control device includes a drive unit board, a power component, a shielding pressure plate, a Hall detector, an AC output copper plate, an output support, a film capacitor, and a radiator. It is characterized in that a long strip-shaped hollow groove is provided in the center of the radiator, copper row feet are provided on the top surface of the film capacitor, the film capacitor is fixed on the lower bottom surface of the radiator, and the copper row feet pass through the long strip-shaped hollow groove;

[0006] The power component, shielding pressure plate, output support, AC output copper plate, and Hall detector are all two sets, and are symmetrically arranged on both sides of the long strip-shaped hollow groove on the radiator. On each side, the output support is fixed on the side of the top surface of the radiator, the Hall detector is installed on the output support, the power component is located on the top surface of the radiator, the electrical input end of the power component is connected to the copper row feet, the electrical output end of the power component is connected to the AC output copper plate, one end of the AC output copper plate passes through the Hall detector and is fixedly connected to the end connecting column of the output support, and the shielding pressure plate is installed on the power component, and both ends of the shielding pressure plate are connected to the top surface of the radiator;

[0007] The described drive unit board is installed above the shielding pressure plate and the power component. The two sides of the drive unit board are respectively fixedly connected to the root connection columns on two sets of output supports, and the drive unit board is electrically connected to the signal pins of the power component.

[0008] Further, the power component includes an upper IGBT and a lower IGBT with the same structure. The upper IGBT and the lower IGBT are arranged side by side in opposite directions on an insulating board. The copper bars on the same side of one side of the upper IGBT and the lower IGBT are the electrical input terminals of the power component, and the copper bars on the other side are the electrical output terminals of the power component.

[0009] Further, the copper bar legs of the film capacitor include four columns of copper bars stacked side by side, and the copper bars are electrically isolated from each other by insulating paper.

[0010] Further, the radiator includes an upper heat dissipation plate and a lower heat dissipation plate with an up-and-down structure. The lower surface of the upper heat dissipation plate is provided with a symmetric first cooling channel and a second cooling channel. The two ends of the first cooling channel are respectively provided with a first water inlet and a first water outlet, the two ends of the second cooling channel are respectively provided with a second water inlet and a second water outlet, and the first water outlet and the second water inlet are communicated with each other.

[0011] Further, the upper surface of the lower heat dissipation plate is provided with a first connection channel, a second connection channel, a third connection channel, a third water outlet and a third water inlet; the two ends of the first connection channel are respectively communicated with the first water outlet and the second water inlet; the two ends of the second connection channel are respectively communicated with the second water outlet and the third water outlet; the two ends of the third connection channel are respectively communicated with the first water inlet and the third water inlet.

[0012] Further, both the first cooling channel and the second cooling channel are rectangular parallelepiped cavity structures, and elliptical heat dissipation pins are arranged in a staggered manner inside the cavity.

[0013] Further, there are two concave arc-shaped ribs in the middle of the shielding pressure plate for pressing the power component.

[0014] Further, the power component and the AC output copper plate are fixedly connected by bolts.

[0015] Further, the power component and the AC output copper plate are connected by laser welding.

[0016] Further, a plurality of fixed fulcrums are distributed on the outer circle of the radiator, and other components can be connected by bolts.

[0017] Compared with the prior art, the present invention has the following beneficial effects:

[0018] 1. The present invention integrates electrical components such as power components, two sets of thin-film capacitor blocks, two sets of Hall detectors, two sets of shielding pressure plates, two sets of AC output copper plates, and a drive unit board on a radiator. The thin-film capacitor blocks are fixed to the bottom surface of the radiator and connected to the power module, forming a highly integrated integrated two-motor control system. All components rely on the radiator for fixation, ensuring the stability and reliability of the entire control device, reducing the volume of the entire control device, and improving the modularity. Moreover, this highly integrated control device can be directly installed as a whole or removed from the controller box during assembly, which not only improves the assembly efficiency, but also enhances the maintainability and repairability of the control device, as well as the integration and flexibility of the product.

[0019] 2. The present invention basically adopts a symmetric arrangement method. The symmetric arrangement of most parts can achieve the common use of components, avoid identical parts, reduce the types and quantities of parts, reduce the interference and inductance of the entire control device, and is conducive to better performance of the entire device.

[0020] 3. The IGBTs in the power component are symmetrically arranged, resulting in good current and voltage performance of the system, small inductance, effectively avoiding the generation of voltage spikes and current spikes, and reducing the probability of IGBT failure.

[0021] 4. The radiator is composed of an upper radiator plate and a lower radiator plate. After the two radiator plates are assembled, a series-connected dual-drive system cooling channel is formed. During operation, the coolant first flows into the third connection channel from the third water inlet, then enters the first water inlet and the first cooling channel, then flows out from the first water outlet, enters the first connection channel, then enters the second water inlet and flows into the second cooling channel, then flows out from the second water outlet, enters the second connection channel, and finally flows out of the radiator from the third water outlet, completing the efficient cooling of the entire control device.

[0022] 5. A plurality of fixed supports are provided on the outer circle of the radiator. When assembling between components, all components can be integrally fixed through bolts. This connection method is simple and easy to implement, low in cost, and suitable for mass production. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 is an exploded view of the structure of the present invention.

[0024] Figure 2 is a schematic structural diagram of the power unit.

[0025] Figure 3 is a schematic structural diagram of the thin-film capacitor.

[0026] Figure 4 is a schematic structural diagram of the AC output copper plate.

[0027] Figure 5 It is a schematic structural diagram of the output support.

[0028] Figure 6 It is a schematic structural diagram of the radiator.

[0029] Figure 7 It is a schematic structural diagram of the upper heat dissipation plate.

[0030] Figure 8 It is a schematic structural diagram of the lower heat dissipation plate.

[0031] Figure 9 It is a schematic structural diagram of the shielding pressure plate.

[0032] Annotation of the attached drawings: 1. Driving unit board, 2. Power component, 3. Shielding pressure plate, 4. Hall detector, 5. AC output copper plate, 6. Output support, 7. Thin film capacitor, 8. Radiator, 21. Insulating board, 22. Upper IGBT, 23. Lower IGBT, 24. Electrical output terminal, 25. Positive input terminal, 26. Negative input terminal, 31. Arc-shaped rib, 61. Root connection column, 62. End connection column, 71. Copper row support foot, 72. Fixed fulcrum, 81. Upper heat dissipation plate, 811. First cooling channel, 813. Second cooling channel, 814. First water inlet, 815. First water outlet, 816. Second water inlet, 817. Second water outlet, 82. Lower heat dissipation plate, 821. First connection channel, 823. Second connection channel, 824. Third water outlet, 825. Third water inlet, 826. Third connection channel, 83. Long strip-shaped hollow groove, 84. Installation column, 85. Fixed fulcrum. Specific implementation mode

[0033] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. This embodiment is implemented on the premise of the technical solution of the present invention, and detailed implementation methods and specific operation processes are given, but the protection scope of the present invention is not limited to the following embodiments.

[0034] As Figure 1 shown, the present application proposes an integrated dual-drive system control device, including a driving unit board 1, a power component 2, a shielding pressure plate 3, a Hall detector 4, an AC output copper plate 5, an output support 6, a thin film capacitor 7 and a radiator 8. A long strip-shaped hollow groove 83 is provided in the center of the radiator 8, and a copper row support foot 71 is provided on the top surface of the thin film capacitor 7. Thus, after the top surface of the thin film capacitor 7 and the bottom surface of the radiator 8 are fixed, the copper row support foot 71 passes through the long strip-shaped hollow groove 83 from bottom to top.

[0035] There are two sets each of the power component 2, the shielding pressure plate 3, the output support 6, the AC output copper plate 5, and the Hall detector 4, and they are symmetrically arranged on both sides of the long strip hollow groove 83 on the radiator 8. The specific structure on each side is as follows: The output support 6 is fixed to the side of the top surface of the radiator 8, and the Hall detector 4 is installed on the output support 6. The power component 2 is located on the top surface of the radiator 8. The electrical input end of the power component 2 is connected to the copper bar support leg 71, and the electrical output end of the power component is connected to the AC output copper plate 5. One end of this AC output copper plate 5 passes through the Hall detector 4 and is fixedly connected to the end connection column 62 of the output support 6. The shielding pressure plate 3 is installed on the power component 2, and both ends of the shielding pressure plate 3 are fixedly connected to the top surface of the radiator 8.

[0036] The drive unit board 1 is installed above the shielding pressure plate 3 and the power component 2. Both sides of the drive unit board 1 are respectively fixedly connected to the root connection columns 61 on the two sets of output supports 6. The drive unit board 1 is electrically connected to the signal pins of the power component 2. In the entire device, each component relies on the radiator 8 for fixation, ensuring the stability and reliability of the entire control device, reducing the volume of the entire control device, and improving the modularization degree. Moreover, this highly integrated control device can be directly installed as a whole into the controller box or taken out during assembly, which not only improves the assembly efficiency, but also improves the maintainability and repairability of the control device, and also improves the integration and flexibility of this product.

[0037] As Figure 2 shown, each set of power components 2 is composed of three power units. Each power unit includes an insulating board 21, an upper tube IGBT 22, a lower tube IGBT 23, an electrical output end 24, a positive input end 25, and a negative input end 26. The structures of the upper tube IGBT 22 and the lower tube IGBT 23 are exactly the same. They are placed side by side in the reverse direction above the insulating board 21 and fixed by vacuum reflow soldering. One end of the copper bar of the upper tube IGBT 22 and the lower tube IGBT 23 is wider, and one end is narrower. Connecting the narrower copper bar at one end of the upper tube IGBT 22 and the wider copper bar at one end of the lower tube IGBT 23 together is the electrical output end 24 of the power component 2, and this electrical output end 24 is used for electrical connection with the AC output copper plate 5. And on the other side, connecting the wider copper bar at one end of the upper tube IGBT 22 and the narrower copper bar at one end of the lower tube IGBT 23 together is the electrical input end of the power component 2. Among them, the copper bar with a wider width is the positive input end 25, which is electrically connected to the positive input end of the thin film capacitor 7, and the copper bar with a narrower width is the negative input end 26, which is electrically connected to the negative input end of the thin film capacitor 7.

[0038] As Figure 3As shown, the film capacitor 7 is provided with four pairs of symmetrically arranged fixed pivots 72 on both sides for connecting the radiator 8. The negative input terminal and the positive input terminal of the film capacitor 7 are integrated into a copper bar leg 71, which is arranged on the filling surface (top surface) of the film capacitor 7. The copper bar leg 71 is composed of four rows of copper bars stacked side by side, and electrical isolation is achieved by insulating paper between the copper bars. The copper bar ends are horizontally bent, and the bottom surface is inlaid with a fixing nut. The copper bar leg 71 can be easily connected to the electrical input terminal of the power module 2. In another embodiment, the copper bar leg 71 and the electrical input terminal of the power module 2 can also be assembled by fully automatic laser welding, which can also meet the requirements of electrical connection, not only reduce inductance, but also save size.

[0039] like Figure 4 As shown, the AC output copper plate 5 is composed of three L-shaped bent copper bars, and the structure is symmetrical relative to the center.

[0040] like Figure 5 As shown, there are four straight-lined root connection columns 61 and three straight-lined end connection columns 62 on the output support 6. The Hall detector 4 is installed between the root connection column 61 and the end connection column 62. The root connection column 61 is used to be bolted to the drive unit board 1. The end connection column 62 is used to fix the end of the AC output copper plate 5 passing through the Hall detector 4.

[0041] like Figures 6 to 8 As shown, the radiator 8 includes an upper heat sink 81 and a lower heat sink 82. The left and right sides of the radiator 8 are symmetrical, and there are two rectangular bosses on the upper surface of the radiator 8, and there is a mounting column 84 on each side of the boss, which is used to connect the two ends of the shielding plate 3. The bottom surface of the upper heat sink 81 and the upper surface of the lower heat sink 82 are matched and fixed, and sealed by a sealant. There are multiple fixed fulcrums 85 distributed on the outer ring of the radiator 8. When assembling the various components, the integrated fixation of all parts can be achieved by bolts. This connection method is simple and easy, low cost and suitable for mass production.

[0042] The lower surface of the upper heat dissipation plate 81 is provided with a first cooling channel 811, a second cooling channel 813, a first water inlet 814, a first water outlet 815, a second water inlet 816 and a second water outlet 817. The first water inlet 814, the first water outlet 815, the second water inlet 816 and the second water outlet 817 are all cylindrical notches. The first water inlet 814 and the first water outlet 815 are respectively arranged at both ends of the first cooling channel 811 and communicate with it. The second water inlet 816 and the second water outlet 817 are arranged at both ends of the second cooling channel 813 and communicate with it. The first water outlet 815 and the second water inlet 816 communicate on the same side. The first cooling channel 811 and the second cooling channel 813 are symmetrically arranged in parallel and are both rectangular cavity structures. Oval heat dissipation pins are arranged in a staggered manner inside the cavity to improve the heat dissipation efficiency.

[0043] The upper surface of the lower heat dissipation plate 82 is provided with a first connection channel 821, a second connection channel 823, a third connection channel 826, a third water outlet 824 and a third water inlet 825. The first connection channel 821, the second connection channel 823 and the third connection channel 826 are all rectangular groove structures. Both ends of the first connection channel 821 communicate with the first water outlet 815 and the second water inlet 816 respectively; both ends of the second connection channel 823 communicate with the second water outlet 817 and the third water outlet 824 respectively; both ends of the third connection channel 826 communicate with the first water inlet 814 and the third water inlet 825 respectively.

[0044] During operation, the coolant first flows into the third connection channel 826 from the third water inlet 825, then enters the first water inlet 814 and enters the first cooling channel 811, then flows out from the first water outlet 815 and enters the first connection channel 821; then enters the second water inlet 816 and flows into the second cooling channel 813; then flows out from the second water outlet 817 and enters the second connection channel 823, and finally flows out of the radiator from the third water outlet 824, completing the efficient heat dissipation of the entire control device.

[0045] As Figure 9 shown, there are two concave arc-shaped ribs 31 in the middle of the shielding pressing plate 3, which can press the power component 2 to ensure that the power component 2 is closely attached to the radiator 8 during operation, ensuring timely heat dissipation.

[0046] The fixed positions between the above-mentioned components are only the fixed positions in this embodiment. For example, the fixed position between the upper IGBT 22 and the lower IGBT 23 in the power component 2 is just one kind of fixed position in this embodiment. The upper IGBT 22 and the lower IGBT 23 can also be arranged in parallel in a line. In actual operation, the structural change of the power device can also be achieved by changing the fixed positions of the upper IGBT 22 and the lower IGBT 23, as long as the electrical connection structure of these power components 2 meets the requirements. Similarly, in this embodiment, the structural arrangement of the upper heat sink 81 and the lower heat sink 82 adopts a series cooling channel design for the flowing channel, with a simple structure and easy to operate. Similarly, the structure of the parallel water channel output can also be achieved by changing the structure.

[0047] The assembly process of this device is as follows:

[0048] (1) Fix the upper heat sink 81 and the lower heat sink 82 together with bolts, and use sealant to seal the sealing position to form a complete radiator 8.

[0049] (2) Then assemble and fix the thin film capacitor 7 on the bottom surface of the radiator 8.

[0050] (3) The upper IGBT 22 and the lower IGBT 23 of the power unit are arranged side by side and in reverse, and form a power unit through reflow soldering. Three power units form a power component 2.

[0051] (4) Apply thermal grease to the bottom surface of the insulating board 21 of the above power component 2, then press it on the boss on the upper surface of the radiator 8, and use the shielding pressure plate 3 to press the power component 2 tightly above the radiator 8, fix it to the radiator 8 and the shielding pressure plate 3 with bolts, and use bolts to fix the positive input terminal 25 and the negative input terminal 26 of the power component 2 to the copper row legs 71 of the thin film capacitor 7 respectively.

[0052] (5) Fix the output support 6 on the upper surface of the radiator 8, and then pass the AC output copper plate 5 through the Hall detector 4. One end of the AC output copper plate 5 is connected to the electrical output terminal 24 of the power component 2, and the other end is fixed to the end connection column 62 of the output support 6 with bolts; fix the Hall detector 4 on the output support 6.

[0053] (6) Fix the drive unit board 1 on the root connection column 61 on the upper surface of the output support 6, and solder and fix the signal pins of the power component 2 to the drive unit board 1.

[0054] The preferred specific embodiments of the present invention have been described in detail above. It should be understood that those of ordinary skill in the art can make many modifications and variations based on the concept of the present invention without creative efforts. Therefore, all technical solutions that can be obtained by those skilled in the art in the technical field based on the concept of the present invention through logical analysis, reasoning or limited experiments on the basis of the prior art shall fall within the protection scope determined by the claims.

Claims

1. An integrated dual-drive system control device, characterized in that The invention comprises a drive unit board (1), a power component (2), a shielding pressure plate (3), a Hall detector (4), an AC output copper plate (5), an output support (6), a film capacitor (7) and a radiator (8), wherein the radiator (8) is provided with a long hollow groove (83) in the center, the top surface of the film capacitor (7) is provided with a copper bar support (71), the film capacitor (7) is fixed on the bottom surface of the radiator (8), and the copper bar support (71) passes through the long hollow groove (83); The power component (2), shielding pressure plate (3), output support (6), AC output copper plate (5) and Hall detector (4) are all in two sets and are symmetrically arranged on both sides of the long hollow groove (83) on the heat sink (8). On each side, the output support (6) is fixed to the side edge of the top surface of the heat sink (8), and the Hall detector (4) is installed on the output support (6). The power component (2) is located on the top surface of the heat sink (8). The electrical input end of the power component (2) is connected to the copper bar support foot (71), and the electrical output end (24) of the power component (2) is connected to the AC output copper plate (5). One end of the AC output copper plate (5) passes through the Hall detector (4) and is fixedly connected to the end connection column (62) of the output support (6). The shielding pressure plate (3) is installed on the power component (2), and the two ends of the shielding pressure plate (3) are connected to the top surface of the heat sink (8). The drive unit board (1) is installed above the shielding pressure plate (3) and the power component (2), and the two sides of the drive unit board (1) are respectively fixedly connected to the root connecting columns (61) on the two sets of output supports (6), and the drive unit board (1) is electrically connected to the signal pins of the power component (2).

2. The control device of an integrated dual-drive system according to claim 1, characterized in that, The power assembly (2) comprises an upper IGBT (22) and a lower IGBT (23) of the same structure, the upper IGBT (22) and the lower IGBT (23) being arranged side by side on an insulating plate (21) in opposite directions to each other, the copper busbar on the same side of the insulating plate (21) where the upper IGBT (22) and the lower IGBT (23) are located is the electrical input end of the power assembly (2), and the copper busbar on the other side is the electrical output end (24) of the power assembly (2).

3. The control device of an integrated dual-drive system according to claim 1, characterized in that The copper bar legs (71) of the film capacitor (7) include four rows of copper bars stacked side by side, and the copper bars are electrically isolated by insulating paper.

4. An integrated dual-drive system control device according to claim 1, characterized in that, The radiator (8) comprises an upper heat dissipation plate (81) and a lower heat dissipation plate (82) of an upper and lower structure; the lower surface of the upper heat dissipation plate (81) is provided with a symmetrical first cooling channel (811) and a second cooling channel (813); the first cooling channel (811) is provided with a first water inlet (814) and a first water outlet (815) at both ends thereof; the second cooling channel (813) is provided with a second water inlet (816) and a second water outlet (817) at both ends thereof; the first water outlet (815) and the second water inlet (816) are connected to each other.

5. An integrated dual-drive system control device according to claim 4, characterized in that, On the upper surface of the lower heat dissipation plate (82), there are provided a first connection channel (821), a second connection channel (823), a third connection channel (826), a third water outlet (824) and a third water inlet (825); both ends of the first connection channel (821) are respectively communicated with a first water outlet (815) and a second water inlet (816); both ends of the second connection channel (823) are respectively communicated with a second water outlet (817) and the third water outlet (824); both ends of the third connection channel (826) are respectively communicated with a first water inlet (814) and the third water inlet (825).

6. An integrated dual-drive system control device according to claim 4, characterized in that, Both the first cooling channel (811) and the second cooling channel (813) are rectangular parallelepiped cavity structures, and elliptical heat dissipation pins are arranged in a staggered manner inside the cavities.

7. An integrated dual-drive system control device according to claim 1, characterized in that, There are two concave arc-shaped ribs (31) in the middle of the shielding pressure plate (3) for pressing the power component (2).

8. An integrated dual-drive system control device according to claim 1, characterized in that, The power component (2) and the AC output copper plate (5) are fixedly connected by bolts.

9. The control device of an integrated dual-drive system according to claim 1, characterized in that, The power component (2) and the AC output copper plate (5) are connected by laser welding.

10. An integrated dual-drive system control device according to claim 1, characterized in that, A plurality of fixed fulcrums (85) are distributed on the outer circle of the radiator (8), and other components can be connected by bolts.

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