A control method for improving the service life of an integrated drive system of a motor controller

Abstract

The present invention discloses a control method for improving the service life of a motor controller integrated drive system, which adopts the following operation steps: S10), the battery sends the optimal allowable discharge current target value CurrentMax11 of the current battery to the controller in real time; S20), the controller calculates the optimal allowable discharge current target value CurrentMax22 of the current motor; S30), the controller takes the smaller value between the optimal allowable discharge current target value CurrentMax11 of the current battery and the optimal allowable discharge current target value CurrentMax22 of the current motor as the optimal discharge current target value CurrentMax33 of the current system; S40), realizing the optimal discharge of the motor controller integrated drive system, which is used to improve the service life of the motor and the battery at the same time; the present invention effectively improves the service life of the motor controller integrated drive system, and further facilitates the large-scale popularization and application of the motor controller integrated drive system.

Description

Technical Field

[0001] The present invention belongs to the field of electric vehicle drive, and relates to a battery management technology for an electric vehicle motor drive system, and particularly to a control method for improving the service life of an integrated drive system of a motor controller. Background Art

[0002] The invention patent with the publication number CN113726088A discloses an integrated component of an electric vehicle motor controller and an electric vehicle thereof, including a permanent magnet rotor component installed integrally with an electric vehicle wheel hub and a motor housing, and a stator component located inside the permanent magnet rotor component and installed integrally with a motor shaft. Among them, a controller for realizing drive control of the motor is installed on the end face of the stator component, a liquid injection port for injecting insulating coolant is provided on the motor housing, and at the same time, an air passage extending from the inside of the motor housing to the outside of the motor housing is provided inside the motor shaft, and an air valve is connected to the air passage port located inside the motor housing; this technical solution effectively solves the heat dissipation problem of the integrated component of the electric vehicle motor controller, thus strongly promoting the application process of the integrated component of the electric vehicle motor controller, and also enabling the motor controller product to be standardized and series modularized.

[0003] After the applicant deeply promoted and applied the motor controller integrated component product provided by CN113726088A, it was considered that there is some room for improvement in the battery of the motor controller integrated drive system. Therefore, it is hoped to seek a technical solution to solve this technical problem. Summary of the Invention

[0004] In view of this, the purpose of the present invention is to provide a control method for improving the service life of an integrated drive system of a motor controller, which realizes the dual guarantee effect of the optimal use state of the battery and the optimal use state of the motor, thereby effectively improving the service life of the motor, and preventing fatal failures such as coil burning and demagnetization of the motor caused by high-temperature use; at the same time, it also reduces the battery heating, effectively improves the service life of the battery, and finally strongly improves the service life of the integrated drive system of the motor controller, which is further conducive to the large-scale popularization and application of the integrated drive system of the motor controller.

[0005] Therefore, the technical solution of the present invention is as follows:

[0006] A control method for improving the service life of an integrated drive system of a motor controller, the integrated drive system of the motor controller includes a motor, a controller installed inside the motor for realizing drive control of the motor, and a battery for supplying power to the controller; the controller is connected to the battery through a communication line; wherein, the control method adopts the following operation steps:

[0007] S10), the battery sends the optimal allowable discharge current target value CurrentMax11 of the current battery to the controller in real time;

[0008] S20), the controller calculates the optimal allowable discharge current target value CurrentMax22 of the current motor based on the internal temperature of the motor, the power device parameters of the controller, and the actual operating current CB2 of the current motor;

[0009] S30), the controller takes the smaller value between the optimal allowable discharge current target value CurrentMax11 of the current battery and the optimal allowable discharge current target value CurrentMax22 of the current motor as the optimal discharge current target value CurrentMax33 of the current system;

[0010] S40), the controller realizes the optimal discharge of the motor controller integrated drive system based on the optimal discharge current target value CurrentMax33 of the current system and the actual operating current CC1 of the current motor, so as to improve the service life of the motor and the battery simultaneously.

[0011] Preferably, the step S40) further adopts the following control steps:

[0012] S41), the controller detects the actual operating current CC1 of the current motor;

[0013] S42), if the actual operating current CC1 of the current motor is equal to or less than the optimal discharge current target value CurrentMax33 of the current system, the current operating mode remains unchanged;

[0014] S43), if the actual operating current CC1 of the current motor is greater than the optimal discharge current target value CurrentMax33 of the current system, the controller automatically reduces the duty cycle PWM1 - fixed amount output to the motor; then the steps S41), S42), and S43) are executed cyclically until the actual operating current CC1 of the current motor is equal to or less than the optimal discharge current target value CurrentMax33 of the current system.

[0015] Preferably, the range of the duty cycle PWM1 - fixed amount is 1 - 50%.

[0016] Preferably, in the step S20), the power device parameter is the temperature-discharge curve of the power device; wherein, according to the detected internal temperature of the motor and the temperature-discharge curve, the maximum discharge current CB1 allowed by the current battery is calculated, and the maximum discharge current CB1 allowed by the current battery and the actual operating current CB2 of the current motor are compared, and the smaller value between the two is taken as the optimal allowable discharge current target value CurrentMax22 of the current motor.

[0017] Preferably, the power device refers to the power transistor of the controller; the temperature-discharge curve refers to the Junction temperature-Drain Current curve of the power transistor, which is obtained by querying the parameter manual of the power transistor; wherein, the Junction temperature is the junction temperature of the power transistor, and the Drain Current is the drain current; the actual value of the detected Junction temperature is used as the internal temperature of the motor, and according to the internal temperature of the motor, the corresponding Drain Current value is obtained by referring to the Junction temperature-Drain Current curve of the power transistor, and this Drain Current value is taken as the maximum discharge current CB1 allowed by the current battery.

[0018] Preferably, the range of the Junction temperature is 0-175 °C, and the range of the Drain Current is 0-80 A.

[0019] Preferably, in the step S10), the optimal allowable discharge current target value CurrentMax11 of the current battery is calculated based on the current actual temperature of the battery, the current discharge current of the battery, and the discharge current curve of the battery; wherein, the current actual temperature and the current discharge current of the battery are obtained by real-time detection respectively, and the discharge current curve of the battery is determined in advance according to the parameter specifications of the battery.

[0020] Preferably, the motor includes a permanent magnet rotor assembly integrally installed with an electric vehicle wheel hub and a motor housing, and a stator assembly located inside the permanent magnet rotor assembly and integrally installed with a motor shaft, wherein, the controller is installed on the end face of the stator assembly; the controller is electrically connected to the windings of the stator assembly, and the output wire harness of the controller extends to the outside of the motor housing after passing through the motor shaft.

[0021] Preferably, the Hall wires of the controller are electrically connected to the Hall components of the stator assembly, the phase wires of the controller are electrically connected to the winding phase wires of the stator assembly, and the communication wires, wheel movement signal wires, power supply wires, and start wires of the controller extend to the outside of the motor housing after passing through the motor shaft. Among them, the power supply wire is electrically connected to the battery.

[0022] Preferably, the controller includes a circuit board fixedly installed on the end face of the stator assembly, and the circuit board is sleeved on the outer periphery of the motor shaft; at least part of the stator assembly / and the circuit board are in direct heat conduction contact with the insulating coolant; the controller further includes a heat dissipation aluminum plate fixedly installed on the end face of the stator assembly, and the power tubes arranged on the circuit board are fixedly installed on the heat dissipation aluminum plate located on the outer periphery of the circuit board.

[0023] This application first proposes to integrally install and integrate the controller with the stator assembly of the motor, which not only effectively simplifies the connection structure of wiring harnesses such as Hall wires and phase wires, reduces wire loss, and lowers the conduction resistance of the motor during operation; at the same time, this application specifically proposes a specific control method. This control method first separately determines the optimal allowable discharge current target value CurrentMax11 of the current battery and the optimal allowable discharge current target value CurrentMax22 of the current motor, and then determines the optimal discharge current target value CurrentMax33 of the current system. Combining the actual operating current CC1 of the current motor, it realizes the optimal discharge of the motor controller integrated drive system; through the control method provided by this application, the dual guarantee effect of the optimal use state of the battery and the optimal use state of the motor is achieved, thereby effectively improving the service life of the motor, preventing fatal failures such as coil burning and demagnetization caused by high-temperature use of the motor; at the same time, it also reduces battery heating, effectively improves the service life of the battery, and ultimately strongly improves the service life of the motor controller integrated drive system, further facilitating the large-scale popularization and application of the motor controller integrated drive system. Description of the Drawings

[0024] Figure 1 is the operation step block diagram of the control method under the specific embodiment of this application;

[0025] Figure 2 is Figure 1 the specific operation step block diagram of step S40) in

[0026] Figure 3 is the schematic diagram of the communication connection structure between the motor and the controller under the specific embodiment of this application;

[0027] Figure 4 is the Junction temperature - Drain Current curve of the power tube under the specific embodiment of this application. Detailed implementation mode

[0028] An embodiment of the present invention discloses a control method for improving the service life of a motor controller integrated drive system. The motor controller integrated drive system includes a motor, a controller installed inside the motor for driving and controlling the motor, and a battery for supplying power to the controller. Among them, the controller is connected to the battery through a communication line. The control method adopts the following operation steps:

[0029] S10): The battery sends the optimal allowable discharge current target value CurrentMax11 of the current battery to the controller in real time;

[0030] S20): The controller calculates the optimal allowable discharge current target value CurrentMax22 of the current motor based on the internal temperature of the motor, the power device parameters of the controller, and the actual operating current CB2 of the current motor;

[0031] S30): The controller takes the smaller value between the optimal allowable discharge current target value CurrentMax11 of the current battery and the optimal allowable discharge current target value CurrentMax22 of the current motor as the optimal discharge current target value CurrentMax33 of the current system;

[0032] S40): The controller realizes the optimal discharge of the motor controller integrated drive system based on the optimal discharge current target value CurrentMax33 of the current system and the actual operating current CC1 of the current motor, and at the same time improves the service life of the motor and the battery.

[0033] In order to enable those skilled in the art to better understand the technical solutions in the present invention, the following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0034] Please refer to Figure 1 、 Figure 2 and in combination with Figure 3As shown, a control method for improving the service life of an integrated drive system of a motor controller. The integrated drive system of the motor controller includes a motor, a controller installed inside the motor for driving and controlling the motor, and a battery for supplying power to the controller. The controller is connected to the battery through a communication line. Preferably, in this embodiment, the motor includes a permanent magnet rotor assembly integrally installed with an electric vehicle wheel hub and a motor housing, and a stator assembly located on the inner circumference of the permanent magnet rotor assembly and integrally installed with a motor shaft. Among them, the controller is installed on the end face of the stator assembly. The controller is electrically connected to the windings of the stator assembly, and the output wire harness of the controller extends to the outside of the motor housing after passing through the motor shaft. Preferably, in this embodiment, the Hall wire of the controller is electrically connected to the Hall assembly of the stator assembly, the phase wire of the controller is electrically connected to the winding phase wire of the stator assembly, and the communication line, wheel movement signal line, power supply line, and start line of the controller extend to the outside of the motor housing after passing through the motor shaft. Among them, the power supply line is electrically connected to the battery. Preferably, in this embodiment, the controller includes a circuit board fixedly installed on the end face of the stator assembly, and the circuit board is sleeved on the outer circumference of the motor shaft. At least part of the stator assembly / and the circuit board are in direct heat conduction contact with the insulating coolant. The controller also includes a heat dissipation aluminum plate fixedly installed on the end face of the stator assembly, and the power tubes arranged on the circuit board are fixedly installed on the heat dissipation aluminum plate located on the outer circumference of the circuit board. For further structural solutions of the integrated drive system of the motor controller, reference can be directly made to the content recorded in CN113726088A. When implementing this application, the content recorded in CN113726088A can be directly used as the structural solution of the integrated drive system of the motor controller, and this application can be directly applied during implementation to further improve the integration technology level of the integrated drive system of the motor controller.

[0035] In this embodiment, the control method adopts the following operation steps:

[0036] S10): The battery sends the optimal allowable discharge current target value CurrentMax11 of the current battery to the controller in real time. Preferably, in this step S10), the optimal allowable discharge current target value CurrentMax11 of the current battery is calculated based on the current actual temperature of the battery, the current discharge current of the battery, and the discharge current curve of the battery. Among them, the current actual temperature of the battery and the current discharge current of the battery are obtained by real-time detection respectively, and the discharge current curve of the battery is determined in advance according to the parameter specifications of the battery. The current actual temperature of the battery, the current discharge current of the battery, and the discharge current curve of the battery can be obtained by known methods and known tools. The embodiments of this application do not make special and unique limitations on them, and these are not the innovative technical content of this application either.

[0037] S20), the controller calculates the current optimal allowable discharge current target value CurrentMax22 of the current motor based on the internal temperature of the motor, the power device parameters of the controller, and the actual operating current CB2 of the current motor; preferably, in this step S20), the power device parameters are the temperature-discharge curve of the power device; wherein, according to the detected internal temperature of the motor and the temperature-discharge curve, the maximum allowable discharge current CB1 of the current battery is calculated, and the maximum allowable discharge current CB1 of the current battery and the actual operating current CB2 of the current motor are compared, and the smaller value between the two is taken as the current optimal allowable discharge current target value CurrentMax22; further preferably, in this embodiment, the power device refers to the power transistor of the controller (specifically, it can be a MOS transistor), wherein, please further refer to Figure 4 As shown, the temperature-discharge curve refers to the Junction temperature-Drain Current curve of the power transistor, which is a well-known parameter of the power transistor and can be directly obtained by querying the parameter manual of the power transistor.

[0038] Specifically, in this embodiment, Junction temperature is the junction temperature of the power transistor, and DrainCurrent is the drain current; the actually detected value of Junction temperature is used as the internal temperature of the motor, and according to the internal temperature of the motor, then referring to the Junction temperature-Drain Current curve of the power transistor to obtain the matched Drain Current value, and taking this Drain Current value as the maximum allowable discharge current CB1 of the current battery; specifically preferably, in this embodiment, the range of Junction temperature is 0-175 °C, and the range of DrainCurrent is 0-80 A.

[0039] S30), the controller takes the smaller value between the current optimal allowable discharge current target value CurrentMax11 of the current battery and the current optimal allowable discharge current target value CurrentMax22 of the current motor as the current optimal discharge current target value CurrentMax33 of the current system;

[0040] S40), the controller realizes the optimal discharge of the motor controller integrated drive system based on the current optimal discharge current target value CurrentMax33 of the current system and the actual operating current CC1 of the current motor (which can be detected by a temperature sensor), and at the same time improves the service life of the motor and the battery; further preferably, this step S40) specifically adopts the following control steps:

[0041] S41), the controller detects the actual operating current CC1 of the current motor;

[0042] S42), if the actual operating current CC1 of the current motor is equal to or less than the optimal discharge current target value CurrentMax33 of the current system, the current operating mode remains unchanged;

[0043] S43), if the actual operating current CC1 of the current motor is greater than the optimal discharge current target value CurrentMax33 of the current system, the controller automatically reduces the duty cycle PWM1 - fixed amount output to the motor. Preferably, the range of the duty cycle PWM1 - fixed amount is 1 - 50%, more preferably; then steps S41), S42) and S43) are executed cyclically until the actual operating current CC1 of the current motor is equal to or less than the optimal discharge current target value CurrentMax33 of the current system.

[0044] Through the above embodiments, the present application simultaneously realizes the optimal usage states of the battery and the motor in the motor controller integrated drive system, eliminates fatal faults such as coil burning and demagnetization of the motor in the motor controller integrated drive system caused by high - temperature use, reduces battery heating at the same time, effectively improves the service lives of the motor and the battery, and thus significantly improves the service life of the motor controller integrated drive system, further facilitating the large - scale popularization and application of the motor controller integrated drive system.

[0045] For those skilled in the art, it is obvious that the present invention is not limited to the details of the above - mentioned exemplary embodiments, and without departing from the spirit or basic characteristics of the present invention, the present invention can be implemented in other specific forms. Therefore, from any point of view, the embodiments should be regarded as exemplary and non - restrictive. The scope of the present invention is defined by the appended claims rather than the above description. Therefore, all changes falling within the meaning and scope of the equivalent elements of the claims are intended to be encompassed within the present invention. Any reference signs in the claims should not be regarded as limiting the claimed rights.

[0046] In addition, it should be understood that although this specification is described according to embodiments, not every embodiment only contains an independent technical solution. This narrative way of the specification is only for clarity. Those skilled in the art should regard the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A control method for improving the service life of an integrated drive system of a motor controller. The integrated drive system of the motor controller includes a motor, a controller installed inside the motor for driving and controlling the motor, and a battery for supplying power to the controller. It is characterized in that, The controller is connected to the battery through a communication line; the control method adopts the following operation steps: S10), the battery sends the optimal allowable discharge current target value CurrentMax11 of the current battery to the controller in real time; S20), the controller calculates the optimal allowable discharge current target value CurrentMax22 of the current motor based on the internal temperature of the motor, the power device parameters of the controller, and the actual operating current CB2 of the current motor; In the step S20), the power device parameter is the temperature-discharge curve of the power device; wherein, according to the detected internal temperature of the motor and the temperature-discharge curve, the maximum allowable discharge current CB1 of the current battery is calculated, and the maximum allowable discharge current CB1 of the current battery and the actual operating current CB2 of the current motor are compared, and the smaller value between the two is taken as the optimal allowable discharge current target value CurrentMax22 of the current motor; S30), the controller takes the smaller value between the optimal allowable discharge current target value CurrentMax11 of the current battery and the optimal allowable discharge current target value CurrentMax22 of the current motor as the optimal discharge current target value CurrentMax33 of the current system; S40), the controller realizes the optimal discharge of the motor controller integrated drive system based on the optimal discharge current target value CurrentMax33 of the current system and the actual operating current CC1 of the current motor, so as to simultaneously improve the service life of the motor and the battery; the step S40) further adopts the following control steps: S41), the controller detects the actual operating current CC1 of the current motor; S42), if the actual operating current CC1 of the current motor is equal to or less than the optimal discharge current target value CurrentMax33 of the current system, the current operating mode remains unchanged; S43), if the actual operating current CC1 of the current motor is greater than the optimal discharge current target value CurrentMax33 of the current system, the controller automatically reduces the duty cycle PWM1-fixed amount output to the motor; then the steps S41), step S42) and step S43) are executed cyclically until the actual operating current CC1 of the current motor is equal to or less than the optimal discharge current target value CurrentMax33 of the current system.

2. The control method for improving the service life of the integrated drive system of the motor controller according to claim 1, characterized in that The range of the duty cycle PWM1-fixed amount is 1-50%.

3. The control method for improving the service life of the integrated drive system of the motor controller according to claim 1, wherein, The power device refers to the power transistor of the controller; the temperature-discharge curve refers to the Junction temperature-Drain Current curve of the power transistor, which is obtained by querying the parameter manual of the power transistor; wherein, the Junction temperature is the junction temperature of the power transistor, and the Drain Current is the drain current; the actual value of the detected Junction temperature is used as the internal temperature of the motor, and according to the internal temperature of the motor, the corresponding Drain Current value is obtained by referring to the Junction temperature-Drain Current curve of the power transistor, and this Drain Current value is taken as the maximum discharge current CB1 allowed by the current battery.

4. The control method for increasing the service life of the integrated drive system of the motor controller according to claim 3, characterized in that, The range of the Junction temperature is 0 - 175 °C, and the range of the Drain Current is 0 - 80 A.

5. The control method for increasing the service life of the integrated drive system of the motor controller according to claim 1, wherein In the step S10), the optimal allowable discharge current target value CurrentMax11 of the current battery is calculated based on the current actual temperature of the battery, the current discharge current of the battery, and the discharge current curve of the battery; wherein, the current actual temperature of the battery and the current discharge current of the battery are obtained by real-time detection respectively, and the discharge current curve of the battery is determined in advance according to the parameter specifications of the battery.

6. The control method for increasing the service life of the integrated drive system of the motor controller according to claim 1, wherein, The motor includes a permanent magnet rotor assembly integrally installed with an electric vehicle wheel hub and a motor housing, and a stator assembly located on the inner circumference of the permanent magnet rotor assembly and integrally installed with a motor shaft. Among them, the controller is installed on the end face of the stator assembly; the controller is electrically connected to the windings of the stator assembly, and the output wire harness of the controller extends to the outside of the motor housing after passing through the motor shaft.

7. The control method for improving the service life of the integrated drive system of the motor controller according to claim 6, wherein, The Hall wire of the controller is electrically connected to the Hall assembly of the stator assembly, the phase wire of the controller is electrically connected to the phase wire of the winding of the stator assembly, and the communication wire, wheel movement signal wire, power supply wire, and start wire of the controller extend to the outside of the motor housing after passing through the motor shaft. Among them, the power supply wire is electrically connected to the battery.

8. The control method for increasing the service life of the integrated drive system of the motor controller according to claim 7, characterized in that, The controller includes a circuit board fixedly installed on the end face of the stator assembly, and the circuit board is sleeved on the outer circumference of the motor shaft; at least part of the stator assembly and the circuit board are in direct heat conduction contact with the insulating coolant; the controller further includes a heat dissipation aluminum plate fixedly installed on the end face of the stator assembly, and the power transistors arranged on the circuit board are fixedly installed on the heat dissipation aluminum plate located on the outer circumference of the circuit board.

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