Capacitive module and motor controller

Abstract

The application discloses a capacitor module and a motor controller. The capacitor module comprises a capacitor, a soft copper bar and a first fastener. The capacitor is provided with a positioning groove on a shell thereof. The soft copper bar is electrically connected with the capacitor and has a first connecting hole. The first fastener is matched with the first connecting hole, and a free end of the first fastener is limited in the positioning groove. The technical scheme can simplify the assembly process and improve the assembly efficiency.

Description

Technical Field

[0001] This application relates to the field of automotive parts technology, and in particular to a capacitor module and a motor controller. Background Technology

[0002] In the motor control system of new energy vehicles, due to dimensional tolerances and large connection stresses, some components use soft copper busbars to eliminate dimensional tolerances and connection stresses at the connection points, such as the connection between the bus capacitor copper busbar and the IGBT module copper busbar.

[0003] Because the freedom of the rivet nuts on the soft copper busbars cannot be constrained when using them, a special fixture is currently used to constrain and fix the rivet nuts on the soft copper busbars. Then, fasteners are tightened and removed after the fasteners are tightened. For example, when assembling a bus capacitor and an IGBT module, the special fixture is fixed to the bus capacitor housing, and the rivet nuts on the soft copper busbars are fixed to the special fixture to constrain and fix the soft copper busbars. Then, fasteners are tightened to the rivet nuts, and the clamping force of the fasteners presses and fixes the soft copper busbars on the bus capacitors and the rigid copper busbars on the IGBT modules.

[0004] However, the assembly method using special tooling requires the removal of the special tooling after the fasteners are fastened, making the assembly process complex and inefficient. Summary of the Invention

[0005] The main purpose of this application is to provide a capacitor module and a motor controller that simplify the assembly process and improve assembly efficiency.

[0006] To achieve the above objectives, this application proposes a capacitor module, comprising:

[0007] A capacitor, wherein the capacitor housing is provided with a positioning groove;

[0008] A soft copper busbar, which is electrically connected to the capacitor and has a first connection hole;

[0009] A first fastener engages with the first connecting hole, and the free end of the first fastener is confined within the positioning groove.

[0010] In one embodiment of this application, the bottom of the positioning groove is provided with a boss, and the sum of the height of the boss and the length of the free end of the first fastener is not less than the depth of the positioning groove.

[0011] In one embodiment of this application, the top of the first fastener has a flange, the outer diameter of which is larger than the opening size of the positioning groove.

[0012] In one embodiment of this application, a support platform protrudes from the top outer side of the positioning groove.

[0013] In one embodiment of this application, two support platforms are provided, and the two support platforms are respectively disposed on opposite sides of the positioning groove.

[0014] In one embodiment of this application, the inner wall of the positioning groove and the outer wall of the first fastener form a mating portion, and the mating portion restricts the first fastener from circumferential movement.

[0015] In one embodiment of this application, the mating part includes a first mating surface and a second mating surface. The first mating surface is located on the inner wall of the positioning groove and near the bottom of the positioning groove, and the second mating surface is located on the outer wall of the first fastener and near the bottom of the first fastener.

[0016] In one embodiment of this application, the capacitor further includes a guide positioning structure, the capacitor housing and the guide positioning structure are integrally formed, and the positioning groove is disposed on the guide positioning structure.

[0017] In one embodiment of this application, a plurality of positioning slots are provided, and the plurality of positioning slots are spaced apart along the length direction of the capacitor housing. The soft copper busbar has a plurality of spaced first connecting holes. A plurality of first fasteners are provided, each of the first fasteners cooperating with a first connecting hole, and the free end of each of the first fasteners is restricted within a positioning slot.

[0018] This application also proposes a motor controller, comprising:

[0019] Capacitor module;

[0020] A power module having a hard copper busbar with a second connection hole;

[0021] The second fastener passes through the second connecting hole and cooperates with the first fastener;

[0022] The capacitor module includes:

[0023] A capacitor, wherein the capacitor housing is provided with a positioning groove;

[0024] A soft copper busbar, which is electrically connected to the capacitor and has a first connection hole;

[0025] A first fastener engages with the first connecting hole, and the free end of the first fastener is confined within the positioning groove.

[0026] The capacitor module provided in this embodiment, when assembled with a power module, utilizes fasteners for fastening. During this process, the first fastener, under pressure, moves downwards along a positioning groove. The positioning groove serves as a guide, allowing the first fastener to smoothly insert into the groove until the flexible copper busbar and the first fastener can no longer move downwards. The free end of the first fastener is then confined within the positioning groove, thus positioning the first fastener and consequently the flexible copper busbar, thereby constraining and fixing it. Subsequently, the second fastener tightens, using its clamping force to press and fix the flexible copper busbar on the capacitor module and the rigid copper busbar on the power module. Therefore, when assembling the capacitor module and power module, there is no need to use special tooling to constrain and fix the flexible copper busbar. This not only reduces the cost of special tooling but also saves the steps of fixing and removing special tooling, effectively simplifying the assembly process and improving assembly efficiency. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0028] Figure 1 This is a schematic diagram of the structure of a capacitor module provided in an embodiment of this application;

[0029] Figure 2 This is a cross-sectional view of a capacitor module provided in an embodiment of this application;

[0030] Figure 3 for Figure 2 A magnified view of a section at point A in the middle;

[0031] Figure 4 This is a partial structural cross-sectional view of a motor controller provided in an embodiment of this application;

[0032] Figure 5 for Figure 4 A magnified view of a section at point B in the middle;

[0033] Figure 6 This is a partially exploded view of a motor controller provided in an embodiment of this application.

[0034] Explanation of icon numbers:

[0035]

[0036]

[0037] The realization of the purpose, functional features and advantages of this application will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0038] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0039] It should be noted that if the embodiments of this application involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicators will also change accordingly.

[0040] Furthermore, if the embodiments of this application involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, features defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions of various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed in this application.

[0041] This application proposes a capacitor module 10 and a motor controller 100, which aim to simplify the assembly process and improve assembly efficiency.

[0042] The specific structures of the capacitor module 10 and the motor controller 100 provided in this application will be described below:

[0043] See also Figures 1 to 6 The capacitor module 10 provided in this application embodiment includes a capacitor 11, a flexible copper busbar 13 and a first fastener 14; the housing of the capacitor 11 is provided with a positioning groove 121; the flexible copper busbar 13 is electrically connected to the capacitor 11 and has a first connection hole 131; the first fastener 14 cooperates with the first connection hole 131, and the free end of the first fastener 14 is restricted in the positioning groove 121.

[0044] It is understood that when the capacitor module 10 provided in this application embodiment is assembled with the power module 20, during the process of locking with the second fastener 30, the first fastener 14 will be under pressure and will move downward along the positioning groove 121. The positioning groove 121 plays a guiding role until the first fastener 14 can no longer move downward in the positioning groove 121. The free end of the first fastener 14 will be restricted in the positioning groove 121 to position the first fastener 14, thereby positioning the soft copper busbar 13 and thus constraining and fixing the soft copper busbar 13. After that, the second fastener 30 (such as a screw) begins to tighten, and the clamping force of the second fastener 30 can press and fix the soft copper busbar 13 on the capacitor module 10 and the hard copper busbar 21 on the power module 20. Therefore, when assembling the capacitor module 10 and the power module 20, it is not necessary to use special tooling to constrain and fix the soft copper busbar 13. This not only reduces the cost of special tooling, but also saves the process of fixing and removing special tooling, thereby effectively simplifying the assembly process and improving assembly efficiency.

[0045] In addition, since the structural space at the connection between the soft copper busbar 13 and the hard copper busbar 21 is small, if a special tooling is used to position the soft copper busbar 13, the special tooling is likely to collide with the capacitor module 10 and the power module 20 when the special tooling is removed, which may easily damage the capacitor module 10 and the power module 20. Therefore, eliminating the use of the special tooling can effectively eliminate the above risks.

[0046] It should be noted that the capacitor module 10 may include, but is not limited to, bus capacitors, and the power module 20 may include, but is not limited to, IGBT modules. The capacitor module 10 and the power module 20 may also be other locking structures with soft copper busbars 13 and hard copper busbars 21, respectively.

[0047] For example, the first fastener 14 can be a press-fit nut, which is connected to the soft copper busbar 13, and the rivet hole of the press-fit nut is connected to the first connection hole 131.

[0048] Optionally, the nut post of the first fastener 14 is inserted into the positioning groove 121.

[0049] For example, the flexible copper busbar 13 may include a first connecting part, a second connecting part, and a flexible connecting part. The first connecting part and the second connecting part are connected through the flexible connecting part. The first connecting part is connected to the capacitor 11, and the second connecting part is provided with a first connecting hole. The first connecting part and the second connecting part are rigid copper busbars, and the flexible connecting part is a flexible copper busbar.

[0050] Optionally, the first fastener 14 can also be directly inserted into the first connecting hole 131 of the soft copper busbar 13, so that the riveting hole of the first fastener 14 is connected to the first connecting hole 131 of the soft copper busbar 13.

[0051] In one embodiment, the capacitor 11 may further include a guide positioning structure 12, and a positioning groove 121 is disposed on the guide positioning structure 12. In order to ensure that there is sufficient connection strength between the guide positioning structure 12 and the shell of the capacitor 11, and at the same time to reduce the molding process, the guide positioning structure 12 and the shell of the capacitor 11 can be integrally formed.

[0052] Optional, see also Figure 3 and Figure 5 The bottom of the positioning groove 121 is provided with a boss 1212, and the sum of the height of the boss 1212 and the length of the free end of the first fastener 14 is not less than the depth of the positioning groove 121. After assembly, the bottom end of the first fastener 14 will abut against the platform of the boss 1212, and it can be ensured that the first fastener 14 has at least a portion protruding from the top of the positioning groove 121, so as to facilitate the assembly of the first fastener 14.

[0053] The first fastener 14 moves downward along the positioning groove 121 under pressure. During the movement of the first fastener 14 along the positioning groove 121, when the bottom end of the first fastener 14 abuts against the platform of the boss 1212, it forms a constraint on the first fastener 14 in its axial direction, and thus forms a constraint on the soft copper busbar 13 in the axial direction of the first fastener 14, thereby making it easier to lock the second fastener 30.

[0054] In addition to using the boss 1212 at the bottom of the positioning groove 121 to limit and constrain the axial position of the first fastener 14, a flange 142 can also be provided on the top of the first fastener 14 to limit and constrain the axial position of the first fastener 14.

[0055] In another example, see reference Figure 3 and Figure 5 The first fastener 14 has a flange 142 on its top, and the outer diameter of the flange 142 is larger than the opening size of the positioning groove 121. After being assembled in place, the flange 142 will abut against the outer top of the positioning groove 121.

[0056] The first fastener 14 moves downward along the positioning groove 121 under pressure. During the movement of the first fastener 14 along the positioning groove 121, when the flange 142 of the first fastener 14 abuts against the top outer side of the positioning groove 121, it forms a constraint on the first fastener 14 in its axial direction, thereby forming a constraint on the soft copper busbar 13 in the axial direction of the first fastener 14.

[0057] Optionally, the flange 142 is arranged around the circumference of the first fastener 14. When the flange 142 of the first fastener 14 abuts against the top outer side of the positioning groove 121, the contact area between the flange 142 and the top outer side of the positioning groove 121 can be increased, thereby increasing the axial constraint strength of the soft copper busbar 13 on the first fastener 14.

[0058] In another embodiment, the bottom of the positioning groove 121 is provided with a boss 1212, and the top of the first fastener 14 has a flange 142.

[0059] Furthermore, in conjunction with reference Figure 3 and Figure 5 In the capacitor module 10 provided in this embodiment, a support platform 122 protrudes from the top outer side of the positioning groove 121. After assembly, the bottom surface of the flexible copper busbar 13 will abut against the platform surface of the support platform 122. Optionally, the bottom surface of the connecting portion with the first connecting hole on the flexible copper busbar abuts against the platform surface of the support platform 122.

[0060] The first fastener 14 moves downward along the positioning groove 121 under pressure. During the process of the first fastener 14 being inserted into the positioning groove 121, when the bottom surface of the soft copper busbar 13 abuts against the table surface of the support platform 122, it can also form a constraint on the soft copper busbar 13 in the axial direction of the first fastener 14 to a certain extent. At the same time, the support platform 122 can also support the soft copper busbar 13 to prevent the soft copper busbar 13 from collapsing and deforming.

[0061] Optionally, when a support platform 122 protrudes from the top outer side of the positioning groove 121, the sum of the length of the first fastener 14 and the height of the protrusion 1212 is not less than the depth from the top of the support platform 122 to the bottom of the positioning groove.

[0062] Furthermore, in conjunction with reference Figure 3 and Figure 5 In the capacitor module 10 provided in this application embodiment, there are two support platforms 122, which are respectively arranged on opposite sides of the positioning groove 121.

[0063] The two support platforms 122 constrain the soft copper busbar 13 to a certain extent in the axial direction of the first fastener 14, and also support the soft copper busbar 13 to prevent it from collapsing and deforming to one side.

[0064] Furthermore, in conjunction with reference Figure 3 and Figure 5In the capacitor module 10 provided in this application embodiment, since the cross-sectional shape of the free end of the conventional first fastener 14 is usually cylindrical, in order to prevent relative rotation between the first fastener 14 and the positioning groove 121, a mating part is formed between the inner wall of the positioning groove 121 and the outer wall of the first fastener 14. The mating part is used to restrict the first fastener 14 from circumferential movement; that is, the cross-sectional shape of the bottom end of the positioning groove 121 is non-circular, and the cross-sectional shape of the free end of the first fastener 14 is also non-circular.

[0065] When assembling the capacitor module 10 and the power module 20 using the second fastener 30, the mating part can be used to restrict the circumferential movement of the first fastener 14, thereby constraining the first fastener 14 in its axial rotation direction, and further constraining the soft copper busbar 13 in the axial rotation direction of the first fastener 14. This prevents the contact area between the soft copper busbar 12 of the capacitor module 10 and the hard copper busbar 21 of the power module 20 from being misaligned and not fully overlapping when the capacitor module 10 and the power module 20 are assembled using the second fastener 30, which would cause the copper busbar to overheat.

[0066] Furthermore, in conjunction with reference Figure 3 and Figure 5 In the capacitor module 10 provided in this application embodiment, the mating part includes a first mating surface 1211 and a second mating surface 141. The first mating surface 1211 is located on the inner wall of the positioning groove 121 and close to the bottom of the positioning groove 121, and the second mating surface 141 is located on the outer wall of the first fastener 14 and close to the bottom of the first fastener 14.

[0067] The first fastener 14 is subjected to pressure and moves downward along the positioning groove 121. During the process of inserting the first fastener 14 into the positioning groove 121, the second mating surface 141 will only interfere with the first mating surface 1211 at the very end, so that the second mating surface 141 near the bottom of the first fastener 14 abuts against the first mating surface 1211, thereby preventing the second mating surface 1211 from blocking the first fastener 14 from being smoothly inserted into the positioning groove 121.

[0068] It should be noted that the second mating surface 141 on the outer wall of the first fastener 14 can be obtained by flattening the outer wall of the first fastener 14 near the bottom end, or by cutting off a piece of the outer wall of the first fastener 14 near the bottom end after molding, or by directly molding the outer wall of the first fastener 14 during mold molding.

[0069] Furthermore, in conjunction with reference Figure 1 , Figure 2 and Figure 4In the capacitor module 10 provided in this embodiment, multiple positioning slots 121 are provided, and the multiple positioning slots 121 are spaced apart along the length direction of the capacitor 11 housing. The flexible copper busbar 13 has multiple spaced first connecting holes 131, and multiple first fasteners 14 are provided. Each first fastener 14 cooperates with one first connecting hole 131, and each first fastener 14 is confined within one positioning slot 121. By using multiple second fasteners 30 to cooperate with multiple first fasteners 14 respectively, the assembly stability between the flexible copper busbar 13 and the rigid copper busbar 21 is improved.

[0070] See also Figure 6 This application also provides a motor controller 100, which includes a power module 20, a second fastener 30, and a capacitor module 10 as described above. The specific structure of the capacitor module 10 is detailed in the foregoing embodiments. Since this motor controller 100 adopts all the technical solutions of the foregoing embodiments, it has at least all the beneficial effects brought about by all the technical solutions of all the foregoing embodiments, which will not be repeated here.

[0071] The power module 20 has a hard copper busbar 21, which has a second connection hole 211. The second fastener 30 can be inserted into the second connection hole 211 and cooperate with the first fastener 14. The clamping force of the second fastener 30 when it is fastened can be used to press and fix the soft copper busbar 13 on the capacitor module 10 and the hard copper busbar 21 on the power module 20.

[0072] Optionally, during assembly, the second fastener 30 passes sequentially through the first connecting hole 131 of the soft copper busbar 13 and the second connecting hole 211 of the hard copper busbar 21, and is connected to the first fastener 14. The clamping force when the second fastener 30 is fastened can be used to press and fix the soft copper busbar 13 on the capacitor module 10 and the hard copper busbar 21 on the power module 20.

[0073] In this embodiment, the motor controller 100 can be applied to new energy vehicles, trains, and airplanes.

[0074] The above description is merely a preferred embodiment of this application and does not limit the patent scope of this application. Any equivalent structural transformations made based on the inventive concept of this application and the contents of the specification and drawings of this application, or direct / indirect applications in other related technical fields, are included within the patent protection scope of this application.

Claims

1. A capacitor module, characterized in that, include: A capacitor, wherein the capacitor housing is provided with a positioning groove; A soft copper busbar, which is electrically connected to the capacitor and has a first connection hole; The first fastener mates with the first connecting hole, and the free end of the first fastener is confined within the positioning groove. The first fastener is connected to the soft copper busbar, the rivet hole of the first fastener is connected to the first connecting hole, and the nut post of the first fastener is inserted into the positioning groove. When the second fastener is used for fastening, the first fastener is subjected to pressure and moves downward along the positioning groove until the first fastener no longer moves downward in the positioning groove, so that the free end of the first fastener is restricted in the positioning groove.

2. The capacitor module as described in claim 1, characterized in that, The bottom of the positioning groove is provided with a boss, and the sum of the height of the boss and the length of the free end of the first fastener is not less than the depth of the positioning groove.

3. The capacitor module as described in claim 1, characterized in that, The first fastener has a flange at the top, and the outer diameter of the flange is larger than the opening size of the positioning groove.

4. The capacitor module as described in any one of claims 1 to 3, characterized in that, A support platform protrudes from the top outer side of the positioning groove.

5. The capacitor module as described in claim 4, characterized in that, The support platform is provided in two parts, which are respectively located on opposite sides of the positioning groove.

6. The capacitor module as described in any one of claims 1 to 3, characterized in that, The inner wall of the positioning groove and the outer wall of the first fastener form a mating part, and the mating part restricts the first fastener from circumferential movement.

7. The capacitor module as described in claim 6, characterized in that, The mating part includes a first mating surface and a second mating surface. The first mating surface is located on the inner wall of the positioning groove and near the bottom of the positioning groove, and the second mating surface is located on the outer wall of the first fastener and near the bottom of the first fastener.

8. The capacitor module as described in any one of claims 1 to 7, characterized in that, The capacitor also includes a guide and positioning structure, wherein the capacitor housing and the guide and positioning structure are integrally formed, and the positioning groove is disposed in the guide and positioning structure.

9. The capacitor module as described in any one of claims 1 to 7, characterized in that, The positioning groove is provided in multiple ways, and the multiple positioning grooves are spaced apart along the length direction of the capacitor shell. The soft copper busbar has multiple spaced first connection holes. The first fastener is provided in multiple ways, each first fastener cooperates with a first connection hole, and the free end of each first fastener is restricted in a positioning groove.

10. A motor controller, characterized in that, include: The capacitor module as described in any one of claims 1 to 9; A power module having a hard copper busbar with a second connection hole; The second fastener passes through the second connecting hole and cooperates with the first fastener.

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