A coupling rectifier device for a motor controller

Abstract

The present invention relates to a coupling rectifier device for a motor controller, comprising a coupling bracket, a wiring copper bar, a rectifier core, a rectifier ring, a first rectifier block, a second rectifier block, and a rectifier device; the coupling bracket comprises a core mounting slot, and a rectifier rack distributed on one side of the core mounting slot, the rectifier core being arranged in the core mounting slot; the wiring copper bar on the rectifier rack sequentially passes through the first mounting slot, the second mounting slot, the third mounting slot, and the fourth mounting slot; the rectifier ring is installed in the first mounting slot and surrounds the wiring copper bar; the first rectifier block is installed in the second mounting slot and surrounds the wiring copper bar; the second rectifier block is installed in the fourth mounting slot and surrounds the wiring copper bar; and the rectifier device is installed in the third mounting slot and connected to the wiring copper bar. Compared with the prior art, the present invention can achieve multi-layer purification of the current entering the motor controller from the battery end of the entire vehicle, has excellent anti-interference performance, and can meet the noise performance test requirements of the six channels of the entire vehicle.

Description

Technical Field

[0001] The present invention relates to the field of electric vehicle controllers, in particular to a coupling rectifier device for a motor controller. Background Art

[0002] In recent years, domestic and international markets have continuously increased their demands for performance and driving experience in new energy electric vehicles. Against this backdrop, new energy electric vehicles are rapidly developing towards high power, high density, high integration, multi-functionality, and intelligence. Simultaneously, the power of high-voltage devices onboard vehicles is increasing, along with the increasing number of low-voltage electronic devices and sensors, creating an increasingly complex electromagnetic environment. As one of the three main components of a new energy vehicle, the controller's internal power module generates transient currents and voltages during high-frequency switching, injecting noise pollution into the vehicle's DC high-voltage system. Furthermore, these high-frequency current fluctuations can affect other electronic devices, such as sensors. These impacts not only affect performance but also reduce vehicle safety and reliability during operation. Traditional motor controllers generally use a two-way or fewer rectification scheme to meet the noise testing requirements of early new energy vehicles under load. However, this design is insufficient for the high-performance, highly integrated vehicles of today and tomorrow, making it difficult to meet the higher-level noise testing requirements of the entire vehicle. Therefore, there is an urgent need to design a more effective coupled rectifier device to meet the higher performance requirements of the entire vehicle. Summary of the Invention

[0003] The purpose of the present invention is to provide a coupling rectifier device for a motor controller in order to overcome the defects of the above-mentioned prior art.

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

[0005] A coupling rectifier device for a motor controller includes a coupling bracket, a wiring copper bar, a rectifier core, a rectifier ring, a first rectifier block, a second rectifier block, and a rectifier device;

[0006] The coupling bracket includes a core mounting slot and a rectifier frame distributed on one side of the core mounting slot. The rectifier core is arranged in the core mounting slot. A transfer copper bus is provided on the side of the rectifier core facing the rectifier frame, and an output copper bus is provided on the opposite side.

[0007] The rectifier frame includes a first mounting slot, a second mounting slot, a third mounting slot and a fourth mounting slot arranged in sequence. The wiring copper bar passes through the first mounting slot, the second mounting slot, the third mounting slot and the fourth mounting slot in sequence. The rectifier ring is installed in the first mounting slot and surrounds the wiring copper bar. The first rectifier block is installed in the second mounting slot and surrounds the wiring copper bar. The second rectifier block is installed in the fourth mounting slot and surrounds the wiring copper bar. The rectifier device is installed in the third mounting slot and connected to the wiring copper bar. One end of the wiring copper bar passes through the first mounting slot as a wiring terminal, and the other end passes through the fourth mounting slot to connect to the transfer copper bar.

[0008] Furthermore, the core installation slot is a box structure with an open top, and the output copper busbar and the transfer copper busbar are both "J"-shaped metal sheets, and their grooves are embedded in the side walls of the core installation slot.

[0009] Furthermore, the rectifier core includes a plurality of non-polarity cores, and the plurality of non-polarity cores are fixed in the core mounting groove by epoxy potting.

[0010] Furthermore, the cross-section of the non-polar core is elliptical, and there are at least three of them.

[0011] Furthermore, the first rectifier block includes a first upper rectifier unit and a first lower rectifier unit, the first upper rectifier unit is in a "mountain" shape, the wiring copper bus divides the second mounting slot into three cavities, the first lower rectifier unit is located at the bottom of the second mounting slot and under the wiring copper bus, and the three protrusions of the first upper rectifier unit are inserted into the three cavities and are close to the bottom of the first lower rectifier unit.

[0012] Furthermore, the second rectifier block includes a second upper rectifier unit and a second lower rectifier unit, the second upper rectifier unit is in a "mountain" shape, the wiring copper bus divides the fourth mounting slot into three cavities, the second lower rectifier unit is located at the bottom of the fourth mounting slot and under the wiring copper bus, and the three protrusions of the second upper rectifier unit are inserted into the three cavities and are close to the second lower rectifier unit at the bottom.

[0013] Furthermore, the bottom of the side walls of the second installation groove and the fourth installation groove are provided with side draw-out openings, and the first lower rectifying unit and the second lower rectifying unit are installed in the second installation groove and the fourth installation groove through the side draw-out openings.

[0014] Furthermore, the third mounting slot is divided into a plurality of mounting cavities by the copper busbar and the ribs, and a clamp protruding upward is provided on the copper busbar. The rectifier components are correspondingly installed in each mounting cavity and connected to the clamp on the copper busbar.

[0015] Furthermore, the rectifying ring is a magnetic ring wound with nano-metal film material.

[0016] Furthermore, the first rectifier block and the second rectifier block are both manganese-zinc and nickel-zinc composite modules.

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

[0018] 1. The present invention highly integrates the rectifier core, rectifier ring, first rectifier block, second rectifier block and rectifier devices. The rectifier core is the key link for stabilizing voltage and current. Multiple rectifier devices are highly integrated on one side of the rectifier core. This structure can achieve multi-layer purification of the current entering the motor controller from the vehicle battery end, making it purer, with excellent anti-interference performance, which can meet the six-channel noise performance test requirements of the whole vehicle.

[0019] 2. The coupled rectifier device of the present invention adopts a left-right integrated structure. Half of the coupling bracket is a core mounting slot. The rectifier core is installed in the core mounting slot and connected to "J"-shaped metal sheets on both sides as connecting copper bars. The other half of the coupling bracket is longitudinally divided into multiple mounting slots. Each rectifier block and rectifier device can be directly placed in the mounting slot to complete the connection or surrounding of the wiring copper bar, thereby significantly reducing the occupied space of the device, making the structure compact and easy to assemble; at the same time, the present invention facilitates users to reasonably configure differential-mode devices, common-mode devices and anti-interference modules according to the different electromagnetic environments of different vehicles, and has good adaptability and scalability.

[0020] 3. The rectifier block in the present invention adopts a lower rectifier unit combined with a "mountain" shaped upper rectifier unit to achieve independent winding of the connecting copper bars, thereby improving the effect of filtering out noise.

[0021] 4. The bottom surface of the capacitor coupling bracket is a flat structure, which can be close to the heat dissipation surface of the motor controller base plate, so that the heat generated by the coupling rectifier device during the filtering process can be effectively conducted out, with good heat dissipation performance, which can make the performance of the entire device more efficient and stable. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a structural schematic diagram of the present invention.

[0023] Figure 2 Schematic diagram of the coupling bracket structure.

[0024] Figure 3 Schematic diagram of the structure of the rectifier core.

[0025] Figure 4 This is a schematic diagram of the structure of the wiring copper busbar.

[0026] Figure 5 This is a structural diagram of the rectifier block.

[0027] Figure markings: 1. Coupling bracket, 11. Rectifier frame, 111. First mounting slot, 112. Second mounting slot, 113. Third mounting slot, 114. Fourth mounting slot, 12. Core mounting slot, 13. Side drawer, 2. Wiring busbar, 21. Caliper, 3. Rectifier core, 31. Non-polarity core, 4. Rectifier ring, 5. First rectifier block, 51. First upper rectifier unit, 52. First lower rectifier unit, 6. Second rectifier block, 61. Second upper rectifier unit, 62. Second lower rectifier unit, 7. Rectifier device, 8. Transfer busbar, 9. Output busbar. DETAILED DESCRIPTION

[0028] The present invention is described in detail below with reference to the accompanying drawings and specific embodiments. This embodiment is implemented based on the technical solution of the present invention, and provides a detailed implementation method and specific operation process, but the protection scope of the present invention is not limited to the following embodiments.

[0029] like Figure 1 and Figure 2 As shown, this embodiment provides a coupling rectifier device for a motor controller, including a coupling bracket 1, a wiring copper bus 2, a rectifier core 3, a rectifier ring 4, a first rectifier block 5, a second rectifier block 6 and a rectifier device 7.

[0030] The coupling bracket 1 is a left-right structure. The left coupling bracket 1 is provided with a core mounting slot 12, and the right side is a rectifier frame 11. The rectifier core 3 is set in the core mounting slot 12. The side of the rectifier core 3 facing the rectifier frame 11 is provided with a transfer copper bus 8, and the opposite side is provided with an output copper bus 9. Figure 3 As shown. Specifically, the rectifier core 3 comprises multiple non-polar cores 31 with elliptical cross-sections, secured within the core mounting slot 12 via epoxy potting. The number of non-polar cores 31 is generally at least three, with five being preferred in this embodiment. The core mounting slot 12 is a box-shaped structure with an open top. The output copper busbar 9 and the transfer copper busbar 8 are both "J"-shaped metal sheets, with grooves in the metal sheets fitting into the sidewalls of the core mounting slot 12.

[0031] The rectifier frame 11 includes a first mounting slot 111, a second mounting slot 112, a third mounting slot 113 and a fourth mounting slot 114 arranged in sequence. The wiring copper bus 2 is two conductive plates arranged side by side, such as Figure 4As shown, the connectors sequentially pass through the first mounting slot 111, the second mounting slot 112, the third mounting slot 113, and the fourth mounting slot 114. One end of the copper busbar 2 passes through the first mounting slot 111 as a terminal, and the other end passes through the fourth mounting slot 114 to connect to the adapter copper busbar 8. The rectifier ring 4 is installed in the first mounting slot 111, surrounding the copper busbar 2; the first rectifier block 5 is installed in the second mounting slot 112, surrounding the copper busbar 2; the second rectifier block 6 is installed in the fourth mounting slot 114, surrounding the copper busbar 2; and the rectifier device 7 is installed in the third mounting slot 113, connecting to the copper busbar 2.

[0032] Combine Figure 2 and Figure 5 As shown, the first rectifier block 5 comprises a first upper rectifier unit 51 and a first lower rectifier unit 52. A side opening 13 is provided at the bottom of the sidewall of the second mounting slot 112. The first lower rectifier unit 52 is mounted to the bottom of the second mounting slot 112 through the side opening 13 and positioned below the copper busbar 2. The first upper rectifier unit 51 is shaped like a mountain, and the copper busbar 2 divides the second mounting slot 112 into three cavities. The three protrusions of the first upper rectifier unit 51 fit into the three cavities and rest against the bottom of the first lower rectifier unit 52, forming a horizontal "sun" shape. This allows the first rectifier block 5 to surround the conductive plates within the second mounting slot 112, providing filtering and noise reduction. Similarly, the second rectifier block 6 comprises a second upper rectifier unit 61 and a second lower rectifier unit 62. A side opening 13 is provided at the bottom of the sidewall of the fourth mounting slot 114. The second lower rectifier unit 62 is mounted to the bottom of the fourth mounting slot 114 through the side opening 13 and positioned below the copper busbar 2. The first upper rectifier unit 51 is shaped like a mountain, and the copper busbar 2 divides the fourth mounting slot 114 into three cavities. The three protrusions of the second upper rectifier unit 61 fit into the three cavities, resting against the second lower rectifier unit 62 at the bottom, forming a horizontal "sun" shape. This way, the second rectifier block 6 surrounds the conductive plates within the fourth mounting slot 114, similarly providing filtering and noise reduction.

[0033] The third mounting groove 113 is divided into a plurality of mounting cavities by the copper busbar 2 and the ribs. A clamp 21 protruding upward is provided on the copper busbar 2. Figure 4 After each rectifier device 7 is installed in each mounting cavity, it can be directly connected to the clamp 21 on the copper bus 2, thereby completing the assembly.

[0034] In this embodiment, the rectifier ring 4 is a magnetic ring made of nano-metal film material, which can be used to suppress high-frequency noise in the circuit; the first rectifier block 5 is made of Ni-Zn mixed metal powder sintered to suppress medium-frequency noise in the circuit; the second rectifier block 6 is made of Mn-Zn mixed metal powder sintered to suppress low-frequency noise in the circuit.

[0035] The specific assembly process of this embodiment is as follows:

[0036] First, place the rectifier core 3 inside the rectangular sunken box structure on the left side of the coupling bracket 1, and pour it into the left area of ​​the coupling bracket 1 from the pouring surface; then electrically connect the transfer copper bus 8 of the rectifier core 3 and the transfer end of the wiring copper bus 2 with bolts.

[0037] Next, install the first rectifier block 5, rectifier device 7, and second rectifier block 6 into the second mounting slot 112, third mounting slot 113, and fourth mounting slot 114 on the right side of the coupling bracket 1, respectively. Connect the terminals of each rectifier device 7 in series between the two lead plates of the copper busbar 2 using clamps 21. First, insert the first lower rectifier unit 52 and the second lower rectifier unit 62 into the side holes below their respective mounting slots. Then, insert the first upper rectifier unit 51 into the second mounting slot 112 and the second upper rectifier unit 61 into the third mounting slot 113.

[0038] This completes the installation process of the novel coupled rectifier device for the motor controller of this embodiment. Subsequently, the input end of the copper busbar 2 is connected to the vehicle's high-voltage power system, and the output copper busbar 9 is connected to the power module to achieve the superior purification performance of the present invention.

[0039] The above describes in detail the preferred embodiments of the present invention. It should be understood that those skilled in the art can make numerous modifications and variations based on the concepts of the present invention without inventive effort. Therefore, any technical solutions that can be derived by those skilled in the art through logical analysis, reasoning, or limited experimentation based on the concepts of the present invention and the prior art should be within the scope of protection defined by the claims.

Claims

1. A coupling rectifier device for a motor controller, characterized in that: It comprises a coupling bracket (1), a copper busbar (2), a rectifier core (3), a rectifier ring (4), a first rectifier block (5), a second rectifier block (6) and a rectifier device (7); The coupling bracket (1) comprises a core mounting groove (12) and a rectifier frame (11) distributed on one side of the core mounting groove (12); the rectifier core (3) is arranged in the core mounting groove (12); a transfer copper busbar (8) is provided on the side of the rectifier core (3) facing the rectifier frame (11), and an output copper busbar (9) is provided on the opposite side; The rectifier frame (11) includes a first mounting slot (111), a second mounting slot (112), a third mounting slot (113) and a fourth mounting slot (114) which are arranged in sequence; the wiring copper bar (2) passes through the first mounting slot (111), the second mounting slot (112), the third mounting slot (113) and the fourth mounting slot (114) in sequence; the rectifier ring (4) is installed in the first mounting slot (111) and surrounds the wiring copper bar (2); the first rectifier block (5) is installed in the second mounting slot (112) and surrounds the wiring copper bar (2); The second rectifier block (6) is installed in the fourth installation slot (114) and surrounds the wiring copper busbar (2); the rectifier device (7) is installed in the third installation slot (113) and connected to the wiring copper busbar (2); one end of the wiring copper busbar (2) passes through the first installation slot (111) as a wiring terminal, and the other end passes through the fourth installation slot (114) to connect to the transfer copper busbar (8); the rectifier ring (4) is used to suppress high-frequency noise in the circuit; the first rectifier block (5) is used to suppress medium-frequency noise in the circuit; and the second rectifier block (6) is used to suppress low-frequency noise in the circuit; The third mounting groove (113) is divided into a plurality of mounting cavities by the copper busbar (2) and the ribs. An upwardly protruding clamp (21) is provided on the copper busbar (2). The rectifier device (7) is correspondingly installed in each mounting cavity and connected to the clamp (21) on the copper busbar (2).

2. A coupling rectifier device for a motor controller according to claim 1, characterized in that: The core installation slot (12) is a box structure with an open top, and the output copper busbar (9) and the transfer copper busbar (8) are both "J"-shaped metal sheets, and their grooves are embedded in the side walls of the core installation slot (12).

3. A coupling rectifier device for a motor controller according to claim 1, characterized in that: The rectifier core (3) comprises a plurality of non-polarity cores (31), and the plurality of non-polarity cores (31) are fixed in the core installation groove (12) by epoxy potting.

4. A coupling rectifier device for a motor controller according to claim 3, characterized in that: The cross section of the non-polar core (31) is elliptical, and the number of the cores is at least three.

5. The coupling rectifier device for a motor controller according to claim 1, characterized in that: The first rectifier block (5) comprises a first upper rectifier unit (51) and a first lower rectifier unit (52); the first upper rectifier unit (51) is in a "mountain" shape; the wiring copper busbar (2) divides the second installation slot (112) into three cavities; the first lower rectifier unit (52) is located at the bottom of the second installation slot (112) and below the wiring copper busbar (2); and the three protrusions of the first upper rectifier unit (51) are inserted into the three cavities and then closely adhere to the first lower rectifier unit (52) at the bottom.

6. A coupling rectifier device for a motor controller according to claim 5, characterized in that: The second rectifier block (6) comprises a second upper rectifier unit (61) and a second lower rectifier unit (62); the second upper rectifier unit (61) is in a "mountain" shape; the wiring copper bar (2) divides the fourth installation slot (114) into three cavities; the second lower rectifier unit (62) is located at the bottom of the fourth installation slot (114) and below the wiring copper bar (2); and the three protrusions of the second upper rectifier unit (61) are inserted into the three cavities and then closely contact the second lower rectifier unit (62) at the bottom.

7. A coupling rectifier device for a motor controller according to claim 6, characterized in that: The bottoms of the side walls of the second installation groove (112) and the fourth installation groove (114) are provided with side draw-out openings (13), and the first lower rectification unit (52) and the second lower rectification unit (62) are installed in the second installation groove (112) and the fourth installation groove (114) through the side draw-out openings (13).

8. The coupling rectifier device for a motor controller according to claim 1, characterized in that: The rectifying ring (4) is a magnetic ring formed by winding a nano-metal film material.

9. The coupling rectifier device for a motor controller according to claim 1, characterized in that: The first rectifier block (5) and the second rectifier block (6) are both manganese-zinc and nickel-zinc composite modules.

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