A filter rectifier for a driver

Abstract

This invention relates to a filter rectifier for a drive unit, comprising a rectifier base and two guide plates. The rectifier also includes two ground planes. The rectifier base has a first-stage placement space, a fourth-stage placement space, and an eighth-stage placement space arranged sequentially. The guide plates pass through the first-stage, fourth-stage, and eighth-stage placement spaces. The two ground planes are located on both sides of the rectifier base. A second-stage placement space is located below the first-stage placement space, a seventh-stage placement space is located below the eighth-stage placement space, and a ninth-stage placement space is located above it. Two third-stage placement spaces are located between the first-stage and fourth-stage placement spaces, situated outside the two guide plates. A fifth-stage and a sixth-stage placement space are located at the bottom of the rectifier base. Compared with the prior art, this invention has advantages such as high integration and wide applicability.

Description

Technical Field

[0001] This invention relates to rectifiers for drives, and more particularly to a filter rectifier for drives. Background Technology

[0002] As the switching frequency of the motor driver power module, a core component of electric drive, increases, the problem of electrical and magnetic coupling interference becomes more prominent. The requirements for radiation and conducted interference of the motor driver at the vehicle end are also increasing. Traditional new energy vehicles use inverters to control the drive motor. The motor driver generates electromagnetic interference during operation. Although the motor driver housing is an aluminum alloy shell with good shielding effect, the current from the vehicle battery end will be conducted into the motor driver through the wiring harness. It is very difficult to eliminate this conducted interference. The traditional method is to simply add a magnetic block or a ferrite bead to the PCB. However, the shortcomings of this approach are that there are relatively few corresponding rectification stages, the mounting bracket itself is large, and the installation is relatively scattered. Therefore, it is difficult to rely solely on the mounting bracket to block external interference, and thus it is difficult to meet the requirements of vehicle noise performance testing.

[0003] To improve shielding performance and meet higher-level testing requirements for vehicles, a sufficient number of rectifiers are needed. However, too many rectifiers lead to significant design difficulties and poor versatility. Therefore, there is an urgent need to design a high-efficiency rectifier for drivers to meet the noise performance testing requirements of different types of vehicles. Summary of the Invention

[0004] The purpose of this invention is to provide a filter rectifier for a driver, which provides installation space for nine-order rectifier devices, far exceeding that of traditional 1- or 2-order rectifier assemblies. All rectifier devices are installed inside the rectifier assembly, which has a complex structure and compact size. It can integrate nine rectifier devices into one highly integrated rectifier, which has strong anti-interference performance, a compact structure, and is easier to assemble on an inverter. Furthermore, it can be customized according to the different electromagnetic environments of different vehicles, allowing for flexible matching and addition / reduction, and can meet the noise test level requirements of different vehicles. It has strong compatibility, scalability, and economy.

[0005] The objective of this invention can be achieved through the following technical solutions:

[0006] A filter rectifier for a drive includes a rectifier base and two guide vanes, the rectifier also including two ground planes.

[0007] The rectifier base is provided with a first-stage placement space, a fourth-stage placement space, and an eighth-stage placement space in sequence. The guide plate is arranged through the first-stage placement space, the fourth-stage placement space, and the eighth-stage placement space. Two grounding plates are located on both sides of the rectifier base.

[0008] Below the first-stage placement space is a second-stage placement space; below the eighth-stage placement space is a seventh-stage placement space; above the eighth-stage placement space is a ninth-stage placement space; between the first-stage and fourth-stage placement spaces are two third-stage placement spaces located outside the two guide vanes; and at the bottom of the rectifier base are fifth-stage and sixth-stage placement spaces.

[0009] The first-order, fourth-order, and eighth-order placement spaces are magnetic ring mounting spaces, and the second-order, third-order, fifth-order, sixth-order, seventh-order, and ninth-order placement spaces are pinned rectifier mounting spaces. The second-order, third-order, fifth-order, and seventh-order placement spaces are all connected to the flow guide plate and the ground plane, and the sixth-order and ninth-order placement spaces are connected to the flow guide plate.

[0010] Furthermore, the first-order placement space is provided with two waist-shaped first-order bosses with rectangular holes, and the eighth-order placement space is provided with two eighth-order bosses with rectangular holes.

[0011] Furthermore, the ground plane is strip-shaped and has a first pin for connecting the pin of the second rectifier device in the second-order placement space and a fourth pin for connecting the pin of the seventh rectifier device in the seventh-order placement space, as well as a second pin for connecting the pin of the third rectifier device in the third-order placement space and a third pin for connecting the pin of the fifth rectifier device in the fifth-order placement space. The first pin and the fourth pin extend axially, while the second pin and the third pin are perpendicular to the axial direction.

[0012] Furthermore, a set of buckles is provided on the outer sides of both ends of the fourth-order placement space, and the rectifier also includes a compression spring. The two ends of the compression spring are provided with slots that engage with the two buckles. After the fourth rectifier device in the fourth-order placement space is placed in the fourth-order placement space, it is pressed by the compression spring.

[0013] Furthermore, the surface of the compression spring is provided with two concave pressure plates, and a long strip-shaped stress-relieving hole is provided in the middle of the two concave pressure plates.

[0014] Furthermore, the nine-tiered placement space is provided with de-duplication grooves on both sides.

[0015] Furthermore, a first rectifier is provided in the first-order placement space, and an eighth rectifier is provided in the eighth-order placement space. Both the first and eighth rectifiers are magnetic rings formed by winding a ring-shaped nanocrystalline thin film. A fourth rectifier is provided in the fourth-order placement space. The fourth rectifier is a magnetic ring formed by sintering a mixture of Mn-Zn and Ni-Zn powders.

[0016] Furthermore, the fourth rectifier device set in the fourth-order placement space includes a lower rectifier block and an upper rectifier block. The lower rectifier block is mountain-shaped, and the upper rectifier block is a long strip structure. The upper rectifier block is mounted on the upper rectifier block to form holes through which two guide plates pass.

[0017] Furthermore, the second-order placement space includes two rectangular holes arranged side by side.

[0018] Furthermore, the seventh-order placement space includes two rectangular holes arranged side by side.

[0019] Compared with the prior art, the present invention has the following beneficial effects:

[0020] 1) It provides installation space for nine-order rectifier devices, which is much higher than that of traditional first- or second-order rectifier components. All rectifier devices are installed inside the rectifier. The rectifier has a complex structure and small size. At the same time, it can integrate nine rectifier devices into one unit to form a highly integrated rectifier. This makes the rectifier have strong anti-interference performance, while its structure is compact and easier to assemble on the inverter. It can also be customized according to the different electromagnetic environments of different vehicles, and can be flexibly matched and added or removed. It can meet the noise test level requirements of different vehicles and has strong compatibility, scalability and economy.

[0021] 2) The specially designed ground plane shape can save space and enable connection with various rectifier devices.

[0022] 3) The high-efficiency rectifier has a rectification order of up to 9th order, which is much higher than the traditional 1st to 2nd order rectifier components. Its first rectifier and second rectifier are both magnetic rectifiers made of nano-scale crystal thin film material, which are located on both sides of the rectifier of the present invention. They can block the noise of the whole vehicle circuit from flowing to the inverter side, and can also effectively isolate the noise of the inverter's high-frequency switching process from flowing to the whole vehicle, thus playing a role in bidirectional interference blocking.

[0023] 4) The mounting and pressing method of the fourth rectifier device is conducive to improving assembly efficiency. Attached Figure Description

[0024] Figure 1 This is an exploded view of the structure according to an embodiment of the present invention;

[0025] Figure 2This is a first-view structural schematic diagram of the rectifier holder according to an embodiment of the present invention;

[0026] Figure 3 This is a schematic diagram of the bottom structure of the rectifier holder according to an embodiment of the present invention;

[0027] Figure 4 This is a schematic diagram of the rectifier holder from a second perspective according to an embodiment of the present invention;

[0028] Figure 5 This is a schematic diagram of the guide plate structure according to an embodiment of the present invention;

[0029] Figure 6 This is a schematic diagram of the structure of the first rectifier device according to an embodiment of the present invention;

[0030] Figure 7 This is a schematic diagram of the fourth rectifier device structure according to an embodiment of the present invention;

[0031] Figure 8 This is a schematic diagram of the guide plate structure according to an embodiment of the present invention;

[0032] Figure 9 This is a schematic diagram of the compression spring structure according to an embodiment of the present invention.

[0033] Among them: 1. Rectifier base, 2. Guide plate, 3. First rectifier device, 4. Second rectifier device, 5. Third rectifier device, 6. Fourth rectifier device, 7. Fifth rectifier device, 8. Sixth rectifier device, 9. Seventh rectifier device, 10. Eighth rectifier device, 11. Ninth rectifier device, 12. Guide plate, 13. Compression spring, 1-1. First-order placement space, 1-2. Second-order placement space, 1-3. Third-order placement space, 1-4. Fourth-order placement space, 1-5. Fifth-order placement space, 1-6. Sixth-order placement space, 1-7. Seventh-order placement space, 1-8. Eighth-order placement space, 1- 9. Nine-tier placement space; 1-10. Weight removal groove; 2-1. First welding hole; 2-2. Second welding hole; 2-3. Third welding hole; 2-4. Fourth welding hole; 2-5. Fifth welding hole; 2-6. Sixth welding hole; 3-1. Rectifier hole; 6-1. Lower rectifier block; 6-2. Upper rectifier block; 12-1. First locking foot; 12-2. Second locking foot; 12-3. Third locking foot; 12-4. Fourth locking foot; 13-1. Pressure table; 13-2. Stress relief hole; 13-3. Slot; 1-1-1. First-tier boss; 1-4-1. Snap-on table; 1-8-1. Eighth-tier boss. Detailed Implementation

[0034] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. These embodiments are based on the technical solution of the present invention and provide detailed implementation methods and specific operating procedures. However, the scope of protection of the present invention is not limited to the following embodiments.

[0035] A driver uses a filter rectifier, such as Figures 1 to 4 As shown, the rectifier includes a rectifier base 1 and two guide vanes 2. The rectifier also includes two ground planes 12.

[0036] The rectifier base 1 is provided with a first-stage placement space 1-1, a fourth-stage placement space 1-4, and an eighth-stage placement space 1-8 in sequence. The guide plate 2 is installed through the first-stage placement space 1-1, the fourth-stage placement space 1-4, and the eighth-stage placement space 1-8. Two ground planes 12 are located on both sides of the rectifier base 1.

[0037] Below the first-stage placement space 1-1 is the second-stage placement space 1-2; below the eighth-stage placement space 1-8 is the seventh-stage placement space 1-7; above it is the ninth-stage placement space 1-9; between the first-stage placement space 1-1 and the fourth-stage placement space 1-4 are two third-stage placement spaces 1-3, located outside the two guide vanes 2; at the bottom of the rectifier seat 1 are the fifth-stage placement space 1-5 and the sixth-stage placement space 1-6.

[0038] The first-order placement space 1-1, the fourth-order placement space 1-4, and the eighth-order placement space 1-8 are magnetic ring mounting spaces. The second-order placement space 1-2, the third-order placement space 1-3, the fifth-order placement space 1-5, the sixth-order placement space 1-6, the seventh-order placement space 1-7, and the ninth-order placement space 1-9 are pinned rectifier mounting spaces. The second-order placement space 1-2, the third-order placement space 1-3, the fifth-order placement space 1-5, and the seventh-order placement space 1-7 are all connected to the flow guide plate 2 and the ground plane 12. The sixth-order placement space 1-6 and the ninth-order placement space 1-9 are connected to the flow guide plate 2.

[0039] The first-level placement space 1-1 has two waist-shaped first-level bosses 1-1-1 with rectangular holes, and the eighth-level placement space 1-8 has two eighth-level bosses 1-8-1 with rectangular holes.

[0040] A first rectifier 3 is installed in the first-order placement space 1-1, an eighth rectifier 10 is installed in the eighth-order placement space 1-8, a fourth rectifier 6 is installed in the fourth-order placement space 1-4, a second rectifier 4 can be optionally installed in the second-order placement space 1-2, a third rectifier 5 can be optionally installed in the third-order placement space 1-3, a fifth rectifier 7 can be optionally installed in the fifth-order placement space 1-5, a sixth rectifier 6 can be optionally installed in the sixth-order placement space 1-6, a seventh rectifier 7 can be optionally installed in the seventh-order placement space 1-7, and a ninth rectifier 9 can be optionally installed in the ninth-order placement space 1-9. These leaded rectifiers can be various types of capacitors. In some embodiments, such as Figure 6As shown, the first rectifier 3 and the eighth rectifier 10 are both magnetic rings made of annular nanocrystalline thin films, with two waist-shaped rectifier holes 3-1 on the inner side. The fourth rectifier 6 is a magnetic ring made of Mn-Zn and Ni-Zn mixed powder sintered together.

[0041] It provides installation space for nine-order rectifier devices, far exceeding that of traditional first- or second-order rectifier components. All rectifier devices are installed inside the rectifier unit, which has a complex structure and compact size. It can integrate nine rectifier devices into one unit to form a highly integrated rectifier. This makes the rectifier have strong anti-interference performance, a compact structure, and is easier to assemble on inverters. It can also be customized according to the different electromagnetic environments of different vehicles, allowing for flexible matching and addition / reduction. It can meet the noise test requirements of different vehicles and has strong compatibility, scalability, and economy.

[0042] Two guide plates 2 serve as the positive and negative electrodes, respectively, and both the guide plates 2 and the guide plate 12 are encapsulated within the rectifier base 1. In some embodiments, such as Figure 5 As shown, the flow guide plate 2 is composed of two long strip-shaped conductive copper busbars. Each flow guide plate 2 has six welding holes from left to right, namely the first welding hole 2-1, the second welding hole 2-2, the third welding hole 2-3, the fourth welding hole 2-4, the fifth welding hole 2-5, and the sixth welding hole 2-6. Figure 8As shown, the ground plane 12 is strip-shaped and has a first pin 12-1 for connecting the pin 4 of the second rectifier in the second-order placement space 1-2 and a fourth pin 12-4 for connecting the pin 9 of the seventh rectifier in the seventh-order placement space 1-7, a second pin 12-2 for connecting the pin 5 of the third rectifier in the third-order placement space 1-3 and a third pin 12-3 for connecting the pin 7 of the fifth rectifier in the fifth-order placement space 1-5. The first pin 12-1 and the fourth pin 12-4 extend axially, while the second pin 12-2 and the third pin 12-3 are perpendicular to the axial direction. Specifically, the two terminals of the second rectifier 4 are electrically connected to the first welding hole 2-1 of the positive and negative guide plates 2, and its other two terminals are electrically connected to the first locking pin 12-1 of the guide plate 12; the two terminals of the third rectifier 5 are electrically connected to the second welding hole 2-2 of the positive and negative guide plates 2, and its other two terminals are electrically connected to the second locking pin 12-2 of the guide plate 12; the two terminals of the fifth rectifier 7 are electrically connected to the third welding hole 2-3 of the positive and negative guide plates 2, and its other two terminals are electrically connected to the third locking pin 12-3 of the guide plate 12; the two terminals of the sixth rectifier 8 are electrically connected to the fourth welding hole 2-4 of the positive and negative guide plates 2; the two terminals of the seventh rectifier 9 are electrically connected to the fifth welding hole 2-5 of the positive and negative guide plates 2, and its other two terminals are electrically connected to the fourth locking pin 12-4 of the guide plate 12; and the two terminals of the ninth rectifier 11 are electrically connected to the sixth welding hole 2-6 of the positive and negative guide plates 2.

[0043] The fourth-order placement space 1-4 has a set of latches 1-4-1 on the outer sides of both ends. The rectifier also includes a compression spring 13, such as Figure 9 As shown, the compression spring has slots 13-3 at both ends that engage with two latches 1-4-1. The fourth rectifier 6, located in the fourth-order placement space 1-4, is pressed down by the compression spring 13 after being placed in the space. The surface of the compression spring 13 has two concave pressure platforms 13-1, and a long, narrow stress-relieving hole 13-2 is located between the two concave pressure platforms 13-1. Figure 7 As shown, the fourth rectifier 6 set in the fourth-order placement space 1-4 includes a lower rectifier block 6-1 and an upper rectifier block 6-2. The lower rectifier block 6-1 is mountain-shaped, and the upper rectifier block 6-2 is a long strip structure. The upper rectifier block 6-2 is mounted on the lower rectifier block 6-1 to form holes through which the two guide plates 2 pass.

[0044] The ninth-tier placement spaces 1-9 are equipped with de-weighting grooves 1-10 on both sides. The second-tier placement spaces 1-2 include two rectangular holes arranged side by side, and the seventh-tier placement spaces 1-7 include two rectangular holes arranged side by side, such as... Figure 3As shown, the fifth-order placement spaces 1-5 and the sixth-order placement spaces 1-6 form a "pin" shape. Two circular through-holes are respectively provided on the inner bottom surfaces of the fifth-order placement spaces 1-5 and the sixth-order placement spaces 1-6, penetrating through the upper and lower end faces of the rectifier base 1 for the pins to pass through.

[0045] The specific assembly process of this embodiment is as follows:

[0046] First, the flow guide plate 2, the connection base plate 12, and the lower rectifier block 6-2 of the fourth rectifier device 6 are plastic-coated within the rectifier base 1. Then, the first rectifier device 3 and the eighth rectifier device 10 are placed into the first-order placement space 1-1 and the eighth-order placement space 1-8 of the rectifier base 1.

[0047] Secondly, the second rectifier device 4 is placed within the second-order placement space 1-2 of the rectifier base 1. The two wiring terminals of the second rectifier device 4 are electrically connected to the first welding holes 2-1 of the flow guide plate 2, and its other two terminals are electrically connected to the first clamping feet 12-1 of the guide floor 12; the third rectifier device 5 is placed into the third-order placement space 1-3 of the rectifier base 1. The two wiring terminals of the third rectifier device 5 are electrically connected to the second welding holes 2-2 of the flow guide plate 2, and its other two terminals are electrically connected to the second clamping feet 12-2 of the guide floor 12; the fifth rectifier device 7 and the sixth rectifier device 9 are respectively placed into the fifth-order placement space 1-5 and the sixth-order placement space 1-6 of the rectifier base 1. The two wiring terminals of the fifth rectifier device 7 are electrically connected to the third welding holes 2-3 of the flow guide plate 2, and its other two terminals are electrically connected to the third clamping feet 12-3 of the guide floor 12. The two terminals of the sixth rectifier device 8 are electrically connected to the fourth welding holes 2-4 of the flow guide plate 2; the seventh rectifier device 9 and the ninth rectifier device 11 are respectively placed into the seventh-order placement space 1-7 and the ninth-order placement space 1-9 of the rectifier base 1. The two wiring terminals of the seventh rectifier device 9 are electrically connected to the fifth welding holes 2-5 of the flow guide plate 2, and its other two terminals are electrically connected to the fourth clamping feet 12-4 of the guide floor 12; the two terminals of the ninth rectifier device 11 are electrically connected to the sixth welding holes 2-6 of the flow guide plate 2. Then, the flow guide plate 2, the first rectifier device 3, the second rectifier device 4, the third rectifier device 5, the fifth rectifier device 7, the sixth rectifier device 8, the seventh rectifier device 9, the eighth rectifier device 10, and the ninth rectifier device 11 within the rectifier base are fixed by potting with potting glue.

[0048] Finally, the upper rectifier block 6-2 of the fourth rectifier device 6 is placed above the lower rectifier block 6-1 within the fourth-order placement space 1-4, and the compression spring is clamped on the buckle platform 1-4-1 of the upper rectifier base 1, such that the pressing platform 13-1 of the compression spring 13 presses against the upper rectifier block 6-2.

[0049] Thus, the assembly of an efficient filtering rectifier for a driver is completed.

Claims

1. A filter rectifier for a driver, comprising a rectifier base (1) and two guide plates (2), characterized in that, The rectifier also includes two ground planes (12). The rectifier base (1) is provided with a first-stage placement space (1-1), a fourth-stage placement space (1-4), and an eighth-stage placement space (1-8) in sequence. The guide plate (2) is arranged through the first-stage placement space (1-1), the fourth-stage placement space (1-4), and the eighth-stage placement space (1-8). Two grounding plates (12) are arranged on both sides of the rectifier base (1). Below the first-order placement space (1-1) is a second-order placement space (1-2), below the eighth-order placement space (1-8) is a seventh-order placement space (1-7), and above it is a ninth-order placement space (1-9). Between the first-order placement space (1-1) and the fourth-order placement space (1-4) are two third-order placement spaces (1-3), which are located on the outside of the two guide plates (2). At the bottom of the rectifier seat (1) are a fifth-order placement space (1-5) and a sixth-order placement space (1-6). The first-order placement space (1-1), the fourth-order placement space (1-4), and the eighth-order placement space (1-8) are magnetic ring mounting spaces. The second-order placement space (1-2), the third-order placement space (1-3), the fifth-order placement space (1-5), the sixth-order placement space (1-6), the seventh-order placement space (1-7), and the ninth-order placement space (1-9) are pinned rectifier mounting spaces. The second-order placement space (1-2), the third-order placement space (1-3), the fifth-order placement space (1-5), and the seventh-order placement space (1-7) are all connected to the guide plate (2) and the ground plane (12). The sixth-order placement space (1-6) and the ninth-order placement space (1-9) are connected to the guide plate (2).

2. A filter rectifier for a driver according to claim 1, characterized in that, The first-level placement space (1-1) is provided with two waist-shaped first-level bosses (1-1-1) with rectangular holes, and the eighth-level placement space (1-8) is provided with two eighth-level bosses (1-8-1) with rectangular holes.

3. A filter rectifier for a driver according to claim 1, characterized in that, The ground plane (12) is strip-shaped and has a first pin (12-1) for connecting the pin of the second rectifier (4) in the second-order placement space (1-2) and a fourth pin (12-4) for connecting the pin of the seventh rectifier (9) in the seventh-order placement space (1-7), a second pin (12-2) for connecting the pin of the third rectifier (5) in the third-order placement space (1-3) and a third pin (12-3) for connecting the pin of the fifth rectifier (7) in the fifth-order placement space (1-5). The first pin (12-1) and the fourth pin (12-4) are arranged to extend along the axial direction, and the second pin (12-2) and the third pin (12-3) are arranged perpendicular to the axial direction.

4. A filter rectifier for a driver according to claim 1, characterized in that, The outer sides of both ends of the fourth-order placement space (1-4) are provided with a set of buckles (1-4-1). The rectifier also includes a compression spring (13). Both ends of the compression spring are provided with slots (13-3) that engage with the two buckles (1-4-1). After the fourth rectifier (6) located in the fourth-order placement space (1-4) is placed in the fourth-order placement space (1-4), it is pressed by the compression spring (13).

5. A filter rectifier for a driver according to claim 4, characterized in that, The surface of the compression spring (13) is provided with two concave pressure plates (13-1), and a long strip-shaped stress relief hole (13-2) is provided in the middle of the two concave pressure plates (13-1).

6. A filter rectifier for a driver according to claim 1, characterized in that, The nine-tiered placement space (1-9) is provided with de-duplication grooves (1-10) on both sides.

7. A filter rectifier for a driver according to claim 1, characterized in that, The first-order placement space (1-1) is provided with a first rectifier (3), and the eighth-order placement space (1-8) is provided with an eighth rectifier (10). Both the first rectifier (3) and the eighth rectifier (10) are magnetic rings formed by winding a ring-shaped nanocrystalline thin film. The fourth-order placement space (1-4) is provided with a fourth rectifier (6), and the fourth rectifier (6) is a magnetic ring formed by sintering a mixture of Mn-Zn and Ni-Zn powders.

8. A filter rectifier for a driver according to claim 1, characterized in that, The fourth rectifier (6) set in the fourth-order placement space (1-4) includes a lower rectifier block (6-1) and an upper rectifier block (6-2). The lower rectifier block (6-1) is in the shape of a mountain, and the upper rectifier block (6-2) is a long strip structure. The upper rectifier block (6-2) is mounted on the lower rectifier block (6-1) to form holes for the passage of the two guide plates (2).

9. A filter rectifier for a driver according to claim 1, characterized in that, The second-order placement space (1-2) includes two rectangular holes arranged side by side.

10. A filter rectifier for a driver according to claim 1, characterized in that, The seventh-order placement space (1-7) includes two rectangular holes arranged side by side.

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