A controller assembly, an electric drive system, and a vehicle

Abstract

This application discloses a controller assembly, an electric drive system, and a vehicle, solving the technical problem that existing motor controllers have complex structures and large overall volumes, which are not conducive to vehicle integration. The controller assembly provided in this application includes a housing, control components, and a high-voltage adapter box. The housing integrates a cooling groove for coolant flow, and IGBTs cover the opening of the cooling groove to form a cooling channel. The high-voltage adapter box includes a housing body, a high-voltage connection component for electrical connection, a power connector, and at least one high-voltage connector. The high-voltage adapter box enables electrical connection between a high-voltage DC power supply and high-voltage equipment. This application's controller assembly integrates a water-cooling plate with the housing, reducing the overall size of the controller assembly. By setting the high-voltage adapter box on the housing to provide multiple electrical connectors, the high-voltage wiring harness can be uniformly installed in a specific area, reducing wiring difficulty, improving the integration of the controller assembly, and facilitating vehicle integration.

Description

Technical Field

[0001] This application belongs to the field of motor controller technology, specifically relating to a controller assembly, an electric drive system, and a vehicle. Background Technology

[0002] The motor controller is a crucial component in electric vehicles, used to control the motor's operating status. Motor controllers typically require connection to a high-voltage DC power supply and a DC-DC converter, as well as several necessary sensors, resulting in numerous high-voltage and low-voltage wiring harnesses on the controller. Furthermore, the motor controller, especially its internal IGBTs, generates significant heat, which negatively impacts their lifespan. Therefore, a dedicated water-cooling plate is installed inside the controller to cool the IGBTs, with cooling water circulated through external piping. Consequently, water pipes also need to be connected to the motor controller.

[0003] In existing technologies, motor controllers have many pipelines, resulting in a complex structure and large overall size, which is not conducive to vehicle integration. Summary of the Invention

[0004] To address the aforementioned technical problems, this application provides a highly integrated controller assembly, as well as an electric drive system and vehicle equipped with the controller assembly.

[0005] The technical solution adopted to achieve the purpose of this application is a controller assembly, comprising:

[0006] The housing has a connected control chamber and a cooling tank;

[0007] The control component, located in the control cavity, includes an electrically connected control board, a drive board, an IGBT, a three-phase output copper busbar, and a high-voltage capacitor. The IGBT covers the opening of the cooling tank to form a cooling channel with the cooling tank.

[0008] A high-voltage adapter box includes a box body, a high-voltage connection assembly, a power connector, and at least one high-voltage connector that are electrically connected. The box body is disposed within the housing and has a communicating high-voltage chamber and at least one assembly port. The high-voltage connection assembly is disposed in the high-voltage chamber, and the high-voltage connector is installed in the assembly port. The power connector is installed on the housing or the box body.

[0009] The control chamber is connected to the high-voltage chamber, so that the copper busbar of the high-voltage capacitor extends into the high-voltage chamber and is electrically connected to the high-voltage connector.

[0010] In some embodiments, the housing includes an upper housing and a water-cooled plate, the upper housing and the water-cooled plate forming the control cavity, and the cooling tank is disposed on the water-cooled plate; the drive board, the IGBT and the high-voltage capacitor are all mounted on the water-cooled plate, the control board is mounted on the upper housing, and the control board and the drive board are electrically connected via a connecting cable.

[0011] In some embodiments, the water-cooled plate includes a connected base plate and a housing, the base plate having the cooling groove and a first through hole through which the three-phase output copper busbar passes; the inner cavity of the housing is connected to the control cavity through the first through hole.

[0012] In some embodiments, the housing further includes a lower housing for closing the inner cavity of the housing, the lower housing having a second through hole through which the three-phase input copper busbar of the power supply passes.

[0013] In some embodiments, the control component further includes a current sensor disposed within the cavity of the housing.

[0014] In some embodiments, both the upper housing and the water-cooled plate are provided with operating windows; the upper housing or the water-cooled plate is provided with a waterproof and breathable valve, or at least one of the operating windows is equipped with a waterproof and breathable valve.

[0015] In some embodiments, the housing includes a top cover and a housing wall integrally formed with the upper housing, the assembly port is provided on the housing wall, and the upper housing is provided with an installation port for installing the power connector.

[0016] In some embodiments, the box wall is provided with two assembly ports, which are located on different sides from the mounting port; the number of high-voltage connectors is two, namely a first high-voltage connector for electrical connection with the air conditioner compressor and a second high-voltage connector for electrical connection with DC-DC converter.

[0017] In some embodiments, the high-voltage connection assembly includes a positive copper busbar, a negative copper busbar, and a plurality of connecting wire harnesses; the positive and negative copper busbars are both electrically connected to the power connector and the copper busbar of the high-voltage capacitor; the first high-voltage connector and the second high-voltage connector are connected in parallel between the positive and negative copper busbars through the plurality of connecting wire harnesses; the control assembly further includes a fuse electrically connected to the high-voltage connection assembly.

[0018] In some embodiments, the high-voltage adapter box further includes a mounting base disposed within the box body, on which the positive copper busbar, the negative copper busbar, and the fuse are all mounted; the mounting base has a recessed area, where the electrical connections of the positive copper busbar, the negative copper busbar, the power connector, and the copper busbar of the high-voltage capacitor are located; a baffle is provided on the side wall of the recessed area.

[0019] In some embodiments, the control board is connected to the top plate of the housing; the top plate is provided with a heat dissipation structure, a low-voltage connector electrically connected to the control board, and a receiving portion for accommodating the capacitor of the control board, the heat dissipation structure being positioned opposite to the chip of the control board, and both the low-voltage connector and the receiving portion protruding from the upper surface of the top plate.

[0020] In some embodiments, the inner cavity shape of the receiving portion is adapted to the shape of the capacitor of the control board; the inner cavity of the receiving portion is provided with thermally conductive curable adhesive that wraps the capacitor; the housing is provided with a thermally conductive pad, and the two sides of the thermally conductive pad are in contact with the chip and the heat dissipation structure, respectively.

[0021] In some embodiments, the high-voltage adapter box, the low-voltage connector, and the receiving portion are arranged sequentially along the flow direction of the fluid in the cooling tank.

[0022] Based on the same inventive concept, this application also provides an electric drive system, comprising:

[0023] The housing assembly includes a motor cavity and a shaft gear cavity;

[0024] The aforementioned controller assembly is connected to the housing assembly;

[0025] The shaft teeth are arranged in the shaft tooth cavity;

[0026] At least one motor is disposed in the motor cavity, and the rotor of the motor is connected to the shaft gear through a shaft drive; the three-phase input copper busbar of the motor is electrically connected to the three-phase output copper busbar of the controller assembly.

[0027] In some embodiments, the electric drive system is a hybrid electric drive system, and the motor has two components: a drive motor and a generator. The gear assembly includes a shift mechanism assembly, and the control board of the controller assembly has a shift control module for electrically connecting to the shift motor of the shift mechanism assembly.

[0028] Based on the same inventive concept, this application also provides a vehicle including the above-described electric drive system.

[0029] As can be seen from the above technical solution, the controller assembly provided in this application includes a housing, a control component, and a high-voltage adapter box. The control component is used to control the operating state of the motor of the electric drive system. The housing integrates a cooling tank for coolant circulation, meaning that the housing of this application also functions as a water-cooling plate. The IGBT covers the opening of the cooling tank to form a cooling channel with the cooling tank, allowing the IGBT to directly contact the coolant in the cooling channel, thereby improving the cooling effect of the IGBT. The high-voltage adapter box enables electrical connection between the high-voltage DC power supply and high-voltage equipment (high-voltage capacitors, DC-DC converters, air conditioning compressors, etc.). Electrical conduction between power connectors and high-voltage connectors is achieved through the high-voltage connection component inside the high-voltage adapter box. The number of high-voltage connectors can be set according to the number of high-voltage equipment in the vehicle, allowing the high-voltage adapter box to function as a multi-way electrical connector.

[0030] Compared with existing motor controllers, the controller assembly of this application integrates the water-cooling plate with the housing, which can reduce the size of the controller assembly; by setting a high-voltage adapter box on the housing to realize the function of multiple electrical connectors, the high-voltage wiring harness can be uniformly installed in a certain area, which can reduce the wiring difficulty, improve the integration of the controller assembly, and facilitate vehicle integration. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the controller assembly in an embodiment of this application.

[0032] Figure 2 for Figure 1 Exploded view of the controller assembly.

[0033] Figure 3 for Figure 1 The main view of the controller assembly.

[0034] Figure 4 for Figure 3 AA section view of the controller assembly.

[0035] Figure 5 for Figure 1 Rear view of the controller assembly.

[0036] Figure 6 for Figure 1 The internal structure diagram of the controller assembly after the housing has been removed.

[0037] Figure 7 for Figure 1 A schematic diagram of the upper housing in the controller assembly.

[0038] Figure 8 for Figure 7 Top view of the upper housing in the controller assembly.

[0039] Figure 9 for Figure 8 BB sectional view of the upper housing in the controller assembly.

[0040] Figure 10 for Figure 1 A schematic diagram of the water-cooled plate in the controller assembly.

[0041] Figure 11 for Figure 10 The front view of the water-cooled plate in the controller assembly.

[0042] Figure 12 for Figure 10 Top view of the water-cooled plate in the controller assembly.

[0043] Figure 13 for Figure 1 A top view of the high-voltage junction box in the controller assembly after the top cover of the box has been removed.

[0044] Figure 14 for Figure 13 A schematic diagram of the internal structure of the high-voltage adapter box in the controller assembly.

[0045] Figure 15 for Figure 1 Wiring circuit diagram of the high-voltage junction box in the controller assembly.

[0046] Figure 16 This is an overall structural diagram of the electric drive system in the embodiments of this application.

[0047] Figure 17 for Figure 16 A schematic diagram of the electric drive system after the end cap has been removed.

[0048] Figure 18 for Figure 16 A schematic diagram of the electric drive system after the right housing has been removed.

[0049] Explanation of reference numerals in the attached figures:

[0050] 100 - Controller assembly, 101 - Control chamber, 102 - High-pressure chamber.

[0051] 110-Housing shell; 111-Upper housing; 1111-Top plate; 1112-Heat dissipation structure; 1113-Receiving part; 1114-Through hole; 1115-Third through hole; 1116-Mounting port; 112-Water-cooled plate; 1121-Base plate; 1122-Cover; 1123-Cooling tank; 1124-First through hole; 1125-Capacitor mounting position; 1126-Sealing groove; 113-Lower housing; 1131-Second through hole; 1132-Positioning pin; 114-Operating window; 115-Waterproof and breathable valve; 116-Cover plate; 117-Inlet pipe; 118-Outlet pipe; 119-Sealing ring.

[0052] 120-Control component; 121-Control board; 122-Driver board; 123-IGBT; 124-Three-phase output copper busbar; 125-High voltage capacitor; 126-Current sensor; 127-Low voltage connector; 128-Connecting cable.

[0053] 130-High voltage adapter box; 131-Box body; 1311-Box wall; 1312-Top cover; 1313-Assembly port; 132-High voltage connection assembly; 1321-Positive copper busbar; 1322-Negative copper busbar; 1323-Connecting wire harness; 133-Power connector; 134-High voltage connector; 1341-First high voltage connector; 1342-Second high voltage connector; 135-Fuse; 136-Mounting base; 1361-Recessed area; 1362-Baffle.

[0054] 1000 - Electric drive system; 300 - Housing assembly; 301 - Shaft gear cavity; 302 - Motor cavity; 310 - Right housing; 320 - Left housing; 330 - End cover; 400 - Motor assembly; 401 - Generator; 402 - Drive motor; 500 - Gear shifting mechanism assembly; 600 - Intermediate shaft gear assembly; 700 - Differential assembly; 800 - Input shaft assembly. Detailed Implementation

[0055] To enable those skilled in the art to better understand this application, the technical solution of this application will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0056] Example 1:

[0057] This application provides a controller assembly 100, see [link to relevant documentation] Figures 1 to 6 The system includes a housing 110, a control component 120, and a high-voltage adapter box 130. The control component 120 controls the operating state of the motor in the electric drive system. The housing 110 integrates a cooling groove 1123 for coolant flow, meaning the housing 110 also functions as a water-cooling plate 112. An IGBT 123 covers the opening of the cooling groove 1123, forming a cooling channel with the cooling groove 1123. The IGBT 123 can directly contact the coolant in the cooling channel, thereby improving the cooling effect of the IGBT 123. The high-voltage adapter box 130 enables electrical connection between the high-voltage DC power supply and high-voltage equipment (high-voltage capacitor 125, DC-DC converter, air conditioning compressor, etc.). The high-voltage connection component 132 inside the high-voltage adapter box 130 enables electrical conduction between the power connector 133 and the high-voltage connector 134. The number of high-voltage connectors 134 can be set according to the number of high-voltage equipment in the vehicle, allowing the high-voltage adapter box 130 to function as a multi-way electrical connector.

[0058] See Figure 4 and Figure 12 The housing 110 contains a control cavity 101 and a cooling groove 1123. The cooling groove 1123 is an open recess with its opening facing the control cavity 101. The housing 110 has a split structure, and the specific division method is not limited in this application. For example, the housing 110 can be divided by a horizontal plane to form two housings, or by a vertical plane to form three housings, left, middle, and right. In general, unlike existing motor controllers, the housing 110 of this application does not have a water-cooling plate that is independent of the housing 110. Instead, the cooling groove 1123 is directly provided on the housing 110 for the flow of coolant. It can also be understood that this application incorporates the water-cooling plate as part of the housing 110.

[0059] See details Figure 2 and Figure 3 The housing 110 includes an upper housing 111 and a water-cooled plate 112, which together form a control cavity 101. Bolt holes are provided on both the upper housing 111 and the water-cooled plate 112, and the two are sealed by a sealing ring 119 and then fixed together by bolts. Cooling grooves 1123 are disposed on the water-cooled plate 112, and are formed by a downward-facing recess on the top surface of the water-cooled plate 112. In some embodiments, the number of cooling grooves 1123 is the same as the number of motors. For ease of arrangement, the cooling grooves 1123 are evenly distributed horizontally and connected sequentially. In other embodiments, the cooling groove 1123 can also be a continuous groove, with an open cooling position formed by welding or bonding a sealing plate to the groove opening, creating a number of grooves equal to the number of motors.

[0060] See Figure 4 and Figure 6 The control assembly 120 includes a control board 121, a drive board 122, an IGBT 123, a three-phase output copper busbar 124, and a high-voltage capacitor 125, all electrically connected. The control board 121, drive board 122, IGBT 123, and three-phase output copper busbar 124 are electrically connected in sequence, and the high-voltage capacitor 125 is electrically connected to the IGBT 123. In the control assembly 120, the drive board 122, IGBT 123, and high-voltage capacitor 125 are all mounted on a water-cooled plate 112. To make full use of the installation space, the IGBT 123 and the high-voltage capacitor 125 are arranged side by side in the horizontal direction. The drive board 122 is located above the IGBT 123 and is fixed to the water-cooled plate 112 by screws. The IGBT 123 covers the opening of the cooling tank 1123 to form a cooling flow channel with the cooling tank 1123.

[0061] See details Figures 10 to 12The water-cooled plate 112 includes a connected substrate 1121 and a housing 1122. The substrate 1121 is generally plate-shaped and has a cooling groove 1123 and a first through hole 1124 for the three-phase output copper busbar 124 to pass through. The substrate 1121 has an internal flow channel with an open structure, forming the cooling groove 1123. An inlet pipe 117 and an outlet pipe 118 are installed at the ends of the substrate 1121, communicating with the cooling groove 1123. The housing 1122 is sleeve-shaped and has an inner cavity. The inner cavity of the housing 1122 is connected to the control cavity 101 of the housing 110 through the first through hole 1124, allowing the three-phase output copper busbar 124 to extend into the inner cavity of the housing 1122 after being electrically connected to the IGBT 123 located in the control cavity 101, so as to be electrically connected to the three-phase input copper busbar of the motor extending into the inner cavity of the housing 1122. The substrate 1121 and the cover 1122 can be integrally formed by injection molding or metal casting, or fixedly connected by welding, bonding, bolting or other methods. In this embodiment, both the substrate 1121 and the cover 1122 are made of aluminum alloy and are directly cast.

[0062] Because the cooling tank 1123 has an open opening, to ensure sealing, the substrate 1121 has a sealing groove 1126 on the outer periphery of the opening of the cooling tank 1123. A sealing ring 119 is placed in the sealing groove 1126. The IGBT 123 has a horizontally extending mounting edge. The mounting edge presses against the sealing ring 119 to achieve sealing of the cooling channel. Figure 4 As shown.

[0063] The high-voltage capacitor 125 is mounted beside the IGBT 123; see details below. Figure 12 The substrate 1121 has a capacitor mounting position 1125, which can be a boss protruding from the surface of the substrate 1121 or a recess that matches the high-voltage capacitor 125. In this embodiment, the capacitor mounting position 1125 is a recess to increase the contact area between the high-voltage capacitor 125 and the substrate 1121. To further improve heat dissipation performance, in this embodiment, a thermally conductive component, such as a thermal pad or thermal adhesive, is provided in the capacitor mounting position 1125. This component can quickly transfer the heat from the high-voltage capacitor 125 to the water-cooled plate 112.

[0064] See Figure 2 and Figure 3In some embodiments, the housing 110 further includes a lower housing 113 for sealing the inner cavity of the cover 1122. The lower housing 113 has a second through hole 1131 through which the three-phase input copper busbar of the power supply passes. A sealing ring 119 is provided between the lower housing 113 and the cover 1122 of the water-cooled plate 112, and then they are fixedly connected by bolts. In some embodiments, a positioning structure is provided on the lower housing 113 and / or the water-cooled plate 112. The positioning structure can be a positioning pin or a pin hole. Matching pin holes or positioning pins are provided in the mounting area of ​​the controller assembly 100, thereby enabling the mounting and positioning of the controller assembly 100. See also Figure 2 The bottom surface of the lower housing 113 is provided with a positioning pin 1132, which can be detachably connected to the lower housing 113 or integrally formed.

[0065] See Figure 4 In the control assembly 120, the control board 121 is connected to the top plate 1111 of the housing 110. Specifically, the control board 121 is mounted on the upper housing 111. The inner surface of the upper housing 111 is provided with several columns with threaded holes. The control board 121 is mounted on the columns with screws. The control board 121 and the drive board 122 are electrically connected via a connecting cable 128. In some embodiments, the control assembly 120 further includes a current sensor 126, which is electrically connected to the control board 121 and is located in the inner cavity of the housing 1122.

[0066] In some embodiments, both the upper housing 111 and the water-cooling plate 112 are provided with operation windows 114. The operation window 114 of the upper housing 111 is used for connecting and inserting the ribbon cable 128, and the operation window 114 of the water-cooling plate 112 is used for electrically connecting the three-phase output copper busbar 124 to the three-phase input copper busbar of the motor. A cover plate 116 is provided on the operation window 114. The cover plate 116 can be a metal cover plate 116 or a plastic cover plate 116. The connection method between the cover plate 116 and the upper housing 111 / water-cooling plate 112 can be a detachable method such as screw connection, threaded connection, or snap connection.

[0067] Because the control component 120 generates heat during operation, the pressure within the control cavity 101 will change. To mitigate the impact of these pressure changes, in some embodiments, at least one operating window 114 is equipped with a waterproof and breathable valve 115. The waterproof and breathable valve 115 prevents water from entering the control cavity 101 and the inner cavity of the housing 1122, but allows airflow to pass smoothly through the valve to accommodate pressure changes within the control cavity 101. In other embodiments, cover plates 116 may be installed on each operating window 114, and waterproof and breathable valves 115 may be installed on other parts of the upper housing 111 or the water-cooled plate 112, such as... Figure 5 As shown.

[0068] In the control assembly 120, the number of drive boards 122, IGBTs 123, and three-phase output copper busbars 124 is the same as the number of motors. For a dual-motor electric drive system, two drive boards 122, two IGBTs 123, and two sets of three-phase output copper busbars 124 are required. The control board 121 is an integrated PCB board, and the control chips for each motor are mounted on the control board 121. When this controller assembly 100 is applied to a hybrid electric drive system, especially a hybrid electric drive system with gears, the various sensors and shifting mechanisms in the hybrid electric drive system are also electrically connected to the control board 121, and the control board 121 directly acquires sensor signals and issues shifting control commands.

[0069] Therefore, in order to ensure the normal operation of the control board 121, it is also necessary to cool it down. Cooling can be achieved by installing a cooling fan on the chip of the control board 121; the specific structure can be referenced from the heat dissipation structure of a desktop computer CPU. In some embodiments, a heat dissipation structure is provided on the top plate 1111 of the housing 110 (i.e., the upper plate of the upper housing 111) to cool the control board 121.

[0070] See details Figure 7 The top plate 1111 is provided with a heat dissipation structure 1112, which is positioned opposite to the chip on the control board 121. The heat dissipation structure 1112 can be a heat dissipation fin, heat dissipation pin, or other structure, and this application does not impose any limitations. As one embodiment, the outer surface of the top plate 1111 is provided with a groove, and a plurality of pin structures are distributed at intervals in the groove to form the heat dissipation structure 1112. If the upper shell 111 is a casting, the pin structure can be integrally cast.

[0071] To improve heat dissipation, in some embodiments, a thermal pad (not shown in the figure) is provided in the housing 110. The two sides of the thermal pad contact the chip and the heat dissipation structure 1112 respectively. The thermal pad can be a thermally conductive adhesive coating or a pad with good thermal conductivity. By setting the thermal pad, the chip and the heat dissipation structure 1112 are in complete contact.

[0072] If the control board 121 has a large-capacity capacitor, the capacitor's heat dissipation also needs to be considered. See [link / reference] Figure 7 In some embodiments, the top plate 1111 of the housing 110 (i.e. the upper plate of the upper housing 111) is provided with a receiving portion 1113 for accommodating the capacitor of the control board 121. The receiving portions 1113 all protrude from the upper surface of the top plate 1111. By providing the receiving portions 1113 to accommodate the capacitor, the overall height of the top plate 1111 is avoided, thereby reducing the volume of the controller assembly 100.

[0073] The size of the receiving portion 1113 can be larger than the size of the capacitor or adapted to the shape of the capacitor. At least one of the length and width of the receiving portion 1113 matches the size of the capacitor to provide a certain limiting function, so that the inner surface of the receiving portion 1113 can directly form a limiting structure to prevent the capacitor from failing due to vibration. The inner cavity of the receiving portion 1113 is provided with thermally conductive curable adhesive to wrap the capacitor, so that the capacitor is in full contact with the inner surface of the receiving portion 1113, which meets the heat dissipation requirements of the capacitor. Furthermore, the thermally conductive curable adhesive wrapping the capacitor can further stabilize the capacitor and ensure a stable electrical connection between the capacitor and the control board 121.

[0074] In some embodiments, the top plate 1111 is also provided with a low-voltage connector 127 electrically connected to the control board 121. The low-voltage connector 127 is used to plug in a low-voltage wiring harness plug to meet the communication requirements between the controller assembly 100 and the vehicle ECU. See Figure 8 A through hole 1114 is provided on the top plate 1111. The low-voltage connector 127 is installed in the through hole 1114 and also protrudes from the upper surface of the top plate 1111. The low-voltage connector 127 and the receiving part 1113 are arranged side by side, utilizing the height space created by each other. This does not increase the structural protrusion height of the outer surface of the controller assembly 100 as a whole, and does not affect the normal use and installation of other structural components. In some embodiments, the low-voltage connector 127, the receiving part 1113, and the high-voltage adapter box 130 are arranged sequentially along the flow direction of the fluid in the cooling tank 1123, making full use of the space on the upper surface of the top plate 1111.

[0075] The high-voltage junction box 130 serves as a multi-channel connector in the controller assembly 100, as detailed in [reference needed]. Figure 2 and Figure 13 The high-voltage adapter box 130 includes a box body 131, and electrically connected high-voltage connection components 132, power connectors 133, and at least one high-voltage connector 134. The box body 131 is connected to the housing 110. The box body 131 has a high-voltage chamber 102 for accommodating the high-voltage connection components 132. The box body 131 has at least one mounting port 1313 for installing the power connector 133 and / or at least one high-voltage connector 134. Specifically, in this embodiment, the high-voltage connector 134 is installed in the mounting port 1313, and the power connector 133 is installed on the housing 110 or the box body 131.

[0076] High-voltage connector 134 is used to connect to the connectors of high-voltage equipment in the vehicle, such as DC-DC converters, air conditioning compressors, PDUs (high-voltage distribution boxes), PTCs (car heaters), high-voltage cables, etc. The number of high-voltage connectors 134 depends on actual needs. Power connector 133 is used to connect to a high-voltage DC power plug to obtain electrical energy from a power source (power battery, fuel cell, etc.). In use, the positive and negative copper busbars of the high-voltage DC power plug (not shown in the figure) extend into the high-voltage chamber 102. The body of the high-voltage DC power plug is fixed to the housing 110 or box 131 with screws to prevent the high-voltage DC power plug from loosening. High-voltage capacitor 125 draws power from the high-voltage DC power plug. Since the high-voltage capacitor 125 is installed in the control chamber 101, the control chamber 101 and the high-voltage chamber 102 should be interconnected so that the copper busbars of the high-voltage capacitor 125 extend into the high-voltage chamber 102 and are electrically connected to the high-voltage connector 134.

[0077] See Figure 7 and Figure 13 The high-voltage adapter box 130 has a bottomless structure, including a top cover 1312 and a box wall 1311. The box wall 1311 is integrally formed with the upper housing 111, or fixedly connected and sealed by welding, bonding, or other methods. In this embodiment, the box wall 1311 is integrally formed with the upper housing 111, and the assembly port 1313 is provided on the box wall 1311. A third through hole 1115 is provided in the portion of the upper housing 111 located in the area enclosed by the box wall 1311. The third through hole 1115 connects the high-voltage chamber 102 and the control chamber 101, allowing the copper busbar of the high-voltage capacitor 125 to extend into the high-voltage chamber 102. Considering that the installation position of the high-voltage capacitor 125 is relatively low compared to the high-voltage adapter box 130, in order to facilitate the connection of the copper busbar of the high-voltage capacitor 125, the mounting port 1116 for installing the power connector 133 is provided on the upper housing 111, and its overall height is lower than that of the assembly port 1313. Figure 7 As shown.

[0078] In this embodiment, the box wall 1311 is provided with two assembly ports 1313, and there are two corresponding high-voltage connectors 134, namely a first high-voltage connector 1341 for electrical connection with the air conditioner compressor and a second high-voltage connector 1342 for electrical connection with the DC-DC converter. Figure 15 As shown, the two assembly ports 1313 and the mounting port 1116 are located on different sides to avoid mutual interference between the mating plugs of the first high-voltage connector 1341, the second high-voltage connector 1342, and the power connector 133.

[0079] In some embodiments, the axial directions of the first high-voltage connector 1341 and the power connector 133 are along the vehicle width direction and the vehicle length direction, respectively. The axial direction of the second high-voltage connector 1342 is set at an angle relative to both the vehicle length direction and the vehicle width direction. That is, relative to the vehicle length direction and the width direction, the high-voltage connector of the air conditioning compressor that is connected to the second high-voltage connector 1342 is inclined to avoid structural equipment such as the intake manifold in the engine compartment and avoids interference with them.

[0080] To ensure that each high-voltage device operates relatively independently, in this embodiment, each high-voltage connector 134 is connected in parallel with the power connector 133. See details... Figure 13 and Figure 14 The high-voltage connection assembly 132 includes a positive copper busbar 1321, a negative copper busbar 1322, and several connecting wire harnesses 1323. The positive copper busbar 1321 and the negative copper busbar 1322 are both electrically connected to the copper busbars of the power connector 133 and the high-voltage capacitor 125. That is, the positive copper busbar 1321 and the negative copper busbar 1322 serve as the positive and negative input ports of the high-voltage connection assembly 132, respectively, and are electrically connected to the positive and negative terminals of the power connector 133. The copper busbar of the high-voltage capacitor 125 is also electrically connected to the positive and negative terminals of the power connector 133. In this embodiment, the positive copper busbar 1321 / negative copper busbar 1322, the copper busbar of the high-voltage capacitor 125, and the positive / negative copper busbars 1322 of the power connector 133 are electrically connected by a high-voltage bolt. The first high-voltage connector 1341 and the second high-voltage connector 1342 are connected in parallel between the positive copper busbar 1321 and the negative copper busbar 1322 through several connecting wire harnesses 1323. The connecting wire harnesses 1323 can be copper busbars or wires.

[0081] To improve electrical safety, in some embodiments, see [link to relevant documentation]. Figure 14 and Figure 15 The control component 120 also includes a fuse 135, which is electrically connected to the high-voltage connection component 132. The fuse 135 may be specifically set on the connection branch of the first high-voltage connector 1341 or the second high-voltage connector 1342, which is not limited in this application.

[0082] For ease of installation of the high-voltage connection assembly 132, see [link / reference]. Figure 13 and Figure 14 In some embodiments, the high-voltage junction box 130 further includes a mounting base 136 disposed inside the box body 131. The mounting base 136 is fixedly connected to the box wall 1311 or the upper shell 111. The positive copper busbar 1321, the negative copper busbar 1322 and the fuse 135 are all mounted on the mounting base 136. The connecting wire harness 1323 is specifically made of wire. The wire has a certain degree of flexibility to facilitate the connection between the copper busbar and the connector.

[0083] Considering that power connector 133 needs to be electrically connected to both the positive copper busbar 1321 / negative copper busbar 1322 and the copper busbar of high-voltage capacitor 125, in order to reduce the length of the copper busbar, see [reference needed]. Figure 14 The mounting base 136 has a recessed area 1361, which is opposite to the third through hole 1115. The electrical connections of the positive copper busbar 1321, negative copper busbar 1322, power connector 133, and high-voltage capacitor 125 are located in the recessed area 1361, allowing the power connector 133 and / or the high-voltage capacitor 125 to use straight copper busbars, which can be directly purchased without separate design. The positive copper busbar 1321 and negative copper busbar 1322 are designed with a bent structure, bending downwards from the upper surface of the mounting base 136 and extending to the recessed area 1361.

[0084] Since the recessed area 1361 and the third through hole 1115 are positioned opposite each other, to prevent the bolts connecting the positive copper busbar 1321, negative copper busbar 1322, power connector 133, and high-voltage capacitor 125 from falling off during installation and entering the control cavity 101, see [reference needed]. Figure 14 The side wall of the sunken area 1361 is equipped with a baffle 1362 to completely seal the gap or reduce the gap to the point that the bolt cannot pass through, thereby avoiding the risk of the bolt falling off accidentally.

[0085] Therefore, the controller assembly 100 provided in this embodiment has the following beneficial effects or advantages:

[0086] 1) The controller assembly 100 of this application integrates the water-cooled plate 112 with the housing 110, which can reduce the size of the controller assembly 100; by setting the high-voltage adapter box 130 on the housing 110 to realize the function of multiple power connectors, the high-voltage wiring harness can be uniformly installed in a certain area, which can reduce the wiring difficulty, improve the integration of the controller assembly 100, and facilitate vehicle installation.

[0087] 2) In the controller assembly 100 of this application, the control board 121 and the drive board 122 are respectively connected to the upper housing 111 and the water-cooling plate 112. The installation and fixation of the two circuit boards do not interfere with each other. The ribbon cable on the drive board 122 is assembled into the connector of the control board 121 by opening an operation window 114 in the upper housing 111. According to simulation and test results, compared with the prior art where each circuit board is stacked and fixed on the same housing 110, the modal and vibration test effects of the control board 121 and the drive board 122 of this application are significantly improved compared with the prior art.

[0088] 3) In the controller assembly 100 of this application, the IGBT 123 and the high-voltage capacitor 125 are cooled by setting a water cooling plate 112, the chip of the control board 121 is cooled by setting a heat dissipation structure 1112, and the capacitor of the control board 121 is limited and cooled by setting a housing part 1113, so as to ensure the working stability of the control component 120.

[0089] Example 2:

[0090] Based on the same inventive concept, this application provides an electric drive system 1000, which is equipped with the controller assembly 100 of Embodiment 1 described above. Therefore, the detailed structure of the controller assembly 100 can be referred to Embodiment 1, and will not be repeated here. See also Figures 16 to 18 The electric drive system 1000 includes a housing assembly 300, a gear assembly, a motor assembly 400, and a controller assembly 100 as described in Embodiment 1. The housing assembly 300 has a motor cavity 302 and a gear cavity 301. The controller assembly 100 is connected to the housing assembly 300, specifically to its upper part. The gear assembly is located in the gear cavity 301 of the housing assembly 300, and the motor assembly 400 is located in the motor cavity 302 of the housing assembly 300. The motor assembly 400 includes one or more motors. The rotor of the motor is connected to the shaft of the gear assembly via a shaft drive, and the gear assembly enables motor deceleration and / or gear shifting. The three-phase input copper busbar of the motor is electrically connected to the three-phase output copper busbar 124 of the controller assembly 100.

[0091] To facilitate the assembly of the shaft gears and the installation of the motor, the housing assembly 300 adopts a split structure. See [link / reference]. Figure 16 The housing assembly 300 includes a right housing 310, a left housing 320, and a rear end cover 330 connected in sequence. The right housing 310 and the left housing 320 together form a gear cavity 301 for accommodating the gear teeth, and the left housing 320 and the rear end cover 330 together form a motor cavity 302 for accommodating the motor. Since the left housing 320 is located between the right housing 310 and the rear end cover 330 and has a relatively large volume, in some embodiments, to facilitate the arrangement of the controller assembly 100, the controller assembly 100 is mounted above the left housing 320. A cavity is provided above the left housing 320, and the controller assembly 100 is mounted in this cavity. The cavity contains several positioning structures, such as positioning pins and pin holes. The positioning pins are located within the cavity, and the controller assembly 100 has pin holes. During installation, the positioning pins are aligned with the pin holes, and the controller assembly 100 is lowered, ensuring that the three-phase input copper busbars of the motor are aligned with the three-phase output copper busbars 124 of the controller assembly 100. Then, the controller assembly 100 is fixedly connected to the left housing 320 using bolts. The cavity wall has several drainage holes to ensure that water accumulated in the cavity (rainwater, water splashed during car washing) can be quickly drained.

[0092] In some embodiments, the electric drive system 1000 is a pure electric drive system or a hybrid electric drive system. Taking a dual-motor hybrid electric drive system as an example, the specific structure can be referred to the figure. The two motors 200 of the hybrid electric drive system are a generator 401 and a drive motor 402, respectively. Both the generator 401 and the drive motor 402 are connected to the shaft and gears for transmission.

[0093] See Figure 18 In some embodiments, the gear assembly includes a shift mechanism assembly 500, an intermediate gear assembly 600, a differential assembly 700, and an input shaft assembly 800. All three assemblies are located within the gear cavity 301. The shift mechanism assembly 500 and the intermediate gear assembly 600 engage with the planetary gear set of the input shaft assembly 800 to achieve gear shifting and transmission functions. Power is output to the wheel axle system from the differential assembly 700. The control board 121 of the controller assembly 100 is equipped with a shift control module for electrical connection to the shift motor of the shift mechanism assembly 500. The specific details of the shift mechanism assembly 500, intermediate shaft gear assembly 600, differential assembly 700 and input shaft assembly 800 can be found in the relevant prior art disclosures. For example, the shaft gear structure in the invention application "A Hybrid Power Drive System" with publication number CN113232501A can be adopted, which will not be elaborated here.

[0094] Example 3:

[0095] Based on the same inventive concept, this application also provides a vehicle including the electric drive system 1000 of Embodiment 2 described above. This vehicle can be a pure electric vehicle or a hybrid vehicle. Since this vehicle adopts all the technical solutions of the electric drive system of Embodiment 2 described above, it possesses at least all the beneficial effects brought about by the technical solutions of Embodiment 2 described above, which will not be elaborated upon here.

[0096] The electric drive system based on Embodiment 2 uses the controller assembly 100 of Embodiment 1. For details, see [link to documentation]. Figure 15 The controller assembly 100 has two high-voltage connectors 134 in its high-voltage adapter box 130. The DC-DC converter and the air conditioning compressor wire plugs are respectively connected to the two high-voltage connectors 134. The DC-DC converter wire harness and the low-voltage wire harness of the controller assembly 100 are connected together. The DC-DC converter is installed on the top of the electric drive system 1000 and is positioned lower than the auxiliary water tank to facilitate the discharge of coolant vapor in the auxiliary water tank and to facilitate the exit of the air conditioning compressor wire in the high-voltage adapter box 130.

[0097] Although preferred embodiments of this application have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of this application.

[0098] Obviously, those skilled in the art can make various modifications and variations to this application without departing from the spirit and scope of this application. Therefore, if such modifications and variations fall within the scope of the claims of this application and their equivalents, this application also intends to include such modifications and variations.

Claims

1. A controller assembly, characterized in that, include: The housing has a connected control chamber and a cooling tank; The control component, located in the control cavity, includes an electrically connected control board, a drive board, an IGBT, a three-phase output copper busbar, and a high-voltage capacitor. The IGBT covers the opening of the cooling tank to form a cooling channel with the cooling tank. A high-voltage adapter box includes a box body, a high-voltage connection assembly, a power connector, and at least one high-voltage connector that are electrically connected. The box body is disposed within the housing and has a communicating high-voltage chamber and at least one assembly port. The high-voltage connection assembly is disposed in the high-voltage chamber, and the high-voltage connector is installed in the assembly port. The power connector is installed on the housing or the box body. The control cavity is connected to the high-voltage cavity, so that the copper busbar of the high-voltage capacitor extends into the high-voltage cavity and is electrically connected to the high-voltage connector; The housing includes an upper housing and a water-cooled plate, which together form the control cavity. The cooling tank is disposed on the water-cooled plate. The drive board, the IGBT, and the high-voltage capacitor are all mounted on the water-cooled plate. The control board is mounted on the upper housing, and the control board and the drive board are electrically connected via a connecting cable. The IGBT and high-voltage capacitor are arranged side by side in a horizontal direction, with the driver board located above the IGBT; The IGBT and high-voltage capacitor are arranged side by side on the same horizontal plane.

2. The controller assembly as described in claim 1, characterized in that: The water-cooled plate includes a connected base plate and a cover. The base plate is provided with the cooling groove and a first through hole through which the three-phase output copper busbar passes. The inner cavity of the cover is connected to the control cavity through the first through hole.

3. The controller assembly as described in claim 2, characterized in that: The housing also includes a lower housing for sealing the inner cavity of the cover, the lower housing having a second through hole through which the three-phase input copper busbar of the power supply passes.

4. The controller assembly as described in claim 2, characterized in that: The control component also includes a current sensor, which is located inside the cavity of the housing.

5. The controller assembly as described in any one of claims 1-4, characterized in that: Both the upper housing and the water-cooled plate are provided with operation windows; the upper housing or the water-cooled plate is provided with a waterproof and breathable valve, or at least one of the operation windows is equipped with a waterproof and breathable valve.

6. The controller assembly as described in any one of claims 1-4, characterized in that: The housing includes a top cover and a housing wall integrally formed with the upper housing. The assembly port is provided on the housing wall, and the upper housing is provided with an installation port for installing the power connector.

7. The controller assembly as described in claim 6, characterized in that: The box wall is provided with two assembly ports, which are located on different sides from the mounting port; there are two high-voltage connectors, namely a first high-voltage connector for electrical connection with the air conditioner compressor and a second high-voltage connector for electrical connection with DC-DC converter.

8. The controller assembly as described in claim 7, characterized in that: The high-voltage connection assembly includes a positive copper busbar, a negative copper busbar, and several connecting wire harnesses; the positive and negative copper busbars are electrically connected to the copper busbars of the power connector and the high-voltage capacitor; the first high-voltage connector and the second high-voltage connector are connected in parallel between the positive and negative copper busbars through the several connecting wire harnesses; the control assembly also includes a fuse electrically connected to the high-voltage connection assembly.

9. The controller assembly as described in claim 8, characterized in that: The high-voltage adapter box also includes a mounting base disposed within the box body, and the positive copper busbar, the negative copper busbar, and the fuse are all mounted on the mounting base; the mounting base has a recessed area, and the electrical connection points of the positive copper busbar, the negative copper busbar, the power connector, and the copper busbar of the high-voltage capacitor are located in the recessed area; the side wall of the recessed area is provided with a baffle.

10. The controller assembly as described in any one of claims 1-4, characterized in that: The control board is connected to the top plate of the housing; the top plate is provided with a heat dissipation structure, a low-voltage connector electrically connected to the control board, and a receiving part for accommodating the capacitor of the control board. The heat dissipation structure is positioned opposite to the chip of the control board, and both the low-voltage connector and the receiving part protrude from the upper surface of the top plate.

11. The controller assembly as claimed in claim 10, characterized in that: The inner cavity shape of the receiving part is adapted to the shape of the capacitor of the control board; the inner cavity of the receiving part is provided with thermally conductive curing adhesive to wrap the capacitor; the housing is provided with a thermally conductive pad, and the two sides of the thermally conductive pad are in contact with the chip and the heat dissipation structure, respectively.

12. The controller assembly as claimed in claim 10, characterized in that: The high-voltage adapter box, the low-voltage connector, and the receiving part are arranged sequentially along the flow direction of the fluid in the cooling tank.

13. An electric drive system, characterized in that, include: The housing assembly includes a motor cavity and a shaft gear cavity; The controller assembly according to any one of claims 1-12 is connected to the housing assembly; The shaft teeth are arranged in the shaft tooth cavity; At least one motor is disposed in the motor cavity, and the rotor of the motor is connected to the shaft gear through a shaft drive; the three-phase input copper busbar of the motor is electrically connected to the three-phase output copper busbar of the controller assembly.

14. The electric drive system according to claim 13, characterized in that: The electric drive system is a hybrid electric drive system, and there are two motors, namely a drive motor and a generator; the shaft gear assembly includes a shift mechanism assembly, and the control board of the controller assembly is provided with a shift control module for electrical connection with the shift motor of the shift mechanism assembly.

15. A vehicle, characterized in that: Includes the electric drive system as described in claim 13 or 14.

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