Inverter assembly, electric drive system and vehicle

Abstract

This invention provides an inverter assembly, an electric drive system, and a vehicle. The inverter assembly includes a capacitor assembly, which includes a housing assembly and an output busbar. A portion of the output busbar is located inside the housing assembly, and another portion extends outside the housing assembly. A power module assembly is disposed on one side of one surface of the housing assembly. A DC busbar is provided at a first end of the power module assembly, and multiple AC busbars are provided at a second end of the power module assembly. The DC busbar is connected to the output busbar. The first and second ends of the power module assembly are positioned opposite each other along the thickness direction of the capacitor assembly. An integrated three-phase busbar assembly includes a U-phase busbar, a V-phase busbar, and a W-phase busbar, each connected to an AC busbar. Applying the technical solution of this invention improves the miniaturization of the inverter assembly and the integration of its internal components.

Description

Technical Field

[0001] This invention relates to the field of vehicle technology, and more specifically, to an inverter assembly, an electric drive system, and a vehicle. Background Technology

[0002] With the development of new energy vehicles, miniaturization and high integration of electric drive systems have become a trend. Currently, the most common approach is three-in-one integration, which integrates the motor, inverter, and reducer. Among these, the inverter is often an independent assembly with a low degree of integration, or the inverter, motor, and reducer share a housing, but the internal components of the inverter are assembled within the same housing. This places high demands on production and limits the development of integration. At the same time, as the degree of integration increases, multi-in-one assemblies are gradually becoming the trend, thus placing higher demands on the integration and miniaturization of inverters. Miniaturization also brings about heat issues that urgently need to be addressed. Summary of the Invention

[0003] The main objective of this invention is to provide an inverter assembly, an electric drive system, and a vehicle to solve the problem of insufficient integration of internal components in the inverter in the prior art.

[0004] To achieve the above objectives, according to one aspect of the present invention, an inverter assembly is provided, comprising: a capacitor assembly including a housing assembly and an output busbar, a portion of the output busbar being located within the housing assembly and another portion extending outside the housing assembly; a power module assembly disposed on one side of one surface of the housing assembly, a first end of the power module assembly having a DC busbar and a second end of the power module assembly having a plurality of AC busbars, the DC busbar being connected to the output busbar, wherein the first end and the second end of the power module assembly are disposed opposite to each other along the thickness direction of the capacitor assembly; and an integrated three-phase busbar assembly including a U-phase busbar, a V-phase busbar, and a W-phase busbar, each of the U-phase busbar, V-phase busbar, and W-phase busbar being connected to an AC busbar.

[0005] Furthermore, the housing assembly includes: a first housing, which is formed by die casting of aluminum alloy, and a mounting position is provided on one surface of the first housing; a water channel cover, which is welded to the first housing and is placed on the mounting position, forming a first water channel between the water channel cover and the first housing, and the power module assembly is disposed on one side of the water channel cover.

[0006] Furthermore, the shell assembly is also provided with a second water channel and a third water channel, which are connected to the first water channel. The second water channel is located at the first end of the first water channel, and the third water channel is located at the second end of the first water channel. Both the second and third water channels extend along the width direction of the first shell. One end of the first shell is provided with an inlet pipe, and the other end of the first shell is provided with an outlet pipe. Each of the inlet and outlet pipes is connected to a connecting water pipe. The connecting water pipe is provided with a limiting structure, which is arranged along the circumference of the connecting water pipe. An inlet channel is formed in the inlet pipe, and an outlet channel is formed in the outlet pipe. The inlet channel is connected to the second water channel, and the outlet channel is connected to the third water channel.

[0007] Furthermore, the housing assembly includes a first surface, a second surface, a third surface, and a fourth surface. The first surface is provided with a mounting position. The second and third surfaces are disposed opposite to each other and are connected to both the second and third surfaces. A second water channel is formed on the second surface, and a third water channel is formed on the third surface. The fourth surface is disposed opposite to the first surface and is connected to both the second and third surfaces. A fifth water channel is formed on the fourth surface. The housing assembly also includes a sixth surface, which is connected to the first, second, third, and fourth surfaces. A sixth water channel is formed on the sixth surface. The first, second, third, fifth, and sixth water channels are interconnected.

[0008] Furthermore, the inverter assembly also includes: a pressure plate, which is disposed between the power module assembly and the integrated three-phase busbar assembly; and an elastic gasket, which is placed between the power module assembly and the pressure plate.

[0009] Furthermore, the capacitor assembly also includes: a capacitor core disposed within the first housing; multiple output busbars spaced apart along the length of the first housing, wherein one end of each output busbar is connected to the capacitor core; a Y capacitor disposed within the first housing and located on one side of the capacitor core; a filter magnetic ring disposed within the first housing and located on one side of the capacitor core; and an input busbar, one end of which passes through the filter magnetic ring and connects to the Y capacitor, and the other end of which extends out of the first housing, wherein multiple input busbars spaced apart along the width of the first housing.

[0010] Furthermore, the first housing is provided with four fixing parts, two fixing parts are arranged at intervals with the water inlet pipe, and the other two fixing parts are arranged at intervals with the water outlet pipe. The capacitor assembly also includes a grounding busbar, the first end of which is located inside the first housing and is connected to the Y capacitor, and the second end of which extends out of the first housing and is connected to the fixing part.

[0011] Furthermore, the inverter assembly also includes: a circuit board assembly connected to the first housing, the circuit board assembly including a drive board assembly and a control board assembly, the drive board assembly and the control board assembly being integrally formed, the drive board assembly being located at the bottom of the first housing, the control board assembly extending along the height direction of the first housing, and the control board assembly being provided with signal connectors.

[0012] Furthermore, the integrated three-phase busbar assembly includes an insulating support, with multiple connecting components spaced apart along the length of the insulating support. These connecting components are respectively used for the passage of the U-phase busbar, V-phase busbar, and W-phase busbar to connect with the insulating support. At least one connecting component includes: a mounting block with a connecting block at its center, a first through hole in the center of the connecting block, and a first mounting groove formed between the outer wall surface of the connecting block and the inner wall surface of the mounting block; a magnetic element with a magnetic element disposed within the first mounting groove, a second through hole in the center of the magnetic element, and the connecting block located within the second through hole; and a first cover plate connected to the magnetic element, with a third through hole in the center of the first cover plate, the third through hole communicating with the first through hole to form a clearance channel for the U-phase busbar, V-phase busbar, or W-phase busbar to pass through.

[0013] Furthermore, the integrated three-phase busbar assembly also includes: a PCB board, which is located at the bottom of the insulating bracket and on one side of the mounting block. The PCB board is equipped with a current sensor connector, which is connected to the drive board assembly.

[0014] Furthermore, the inverter assembly also includes: an insulation structure connected to the housing assembly, the insulation structure including a first section, a second section and a third section, the second section and the third section being arranged opposite to each other, the second section and the third section being connected through the first section, a first limiting space being formed between the second section and the third section, a portion of the water channel cover being located within the first limiting space, and the first section being located between the power module assembly and the water channel cover.

[0015] According to another aspect of the present invention, an electric drive system is provided, including an inverter assembly, the inverter assembly being the inverter assembly described above, the electric drive system further including a second housing, the second housing having a receiving cavity, a portion of the inverter assembly being disposed within the receiving cavity, the second housing having a sealing groove, a sealing block being disposed within the sealing groove, a connecting water pipe extending out of the second housing through the sealing block, and the sealing block abutting against a limiting structure.

[0016] Furthermore, the electric drive system also includes: a top cover, which is connected to the second housing; a high-voltage DC connector, which is connected to the input busbar; and a low-voltage connector, which is connected to the signal connector. The second housing has a fourth water channel, and the first housing has a first water outlet channel. The fourth water channel is connected to the first water outlet channel. The second housing has a water channel sealing ring around the outer edge of the fourth water channel, and a portion of the water channel sealing ring abuts against the first housing.

[0017] According to another aspect of the present invention, a vehicle is provided, including an electric drive system, wherein the electric drive system is the electric drive system described above.

[0018] According to the technical solution of this invention, the capacitor assembly includes a housing assembly with an output busbar. The power module assembly is disposed on one side of one surface of the housing assembly. The DC busbar at the first end of the power module assembly is connected to the output busbar. The AC busbars at the second end of the power module assembly are respectively connected to the U-phase busbar, V-phase busbar, and W-phase busbar of the integrated three-phase busbar assembly. The first end and the second end of the power module assembly are arranged opposite to each other along the thickness direction of the capacitor assembly, thereby making the inverter assembly more compact, lighter, and with lower contact resistance, improving the miniaturization of the inverter assembly and the integration of internal components. Attached Figure Description

[0019] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0020] Figure 1 A schematic diagram of the structure of a first embodiment of the inverter assembly according to the present invention is shown;

[0021] Figure 2 A schematic diagram of a second embodiment of the inverter assembly according to the present invention is shown;

[0022] Figure 3 A schematic diagram of a third embodiment of the inverter assembly according to the present invention is shown;

[0023] Figure 4 A schematic diagram of a fourth embodiment of the inverter assembly according to the present invention is shown;

[0024] Figure 5 A schematic diagram of an embodiment of the capacitor assembly according to the present invention is shown;

[0025] Figure 6 A schematic diagram of an embodiment of the integrated three-phase busbar assembly according to the present invention is shown;

[0026] Figure 7 A schematic diagram of an embodiment of the cooperation between the cover plate and the insulating support according to the present invention is shown;

[0027] Figure 8 A schematic diagram of an embodiment of the circuit board assembly according to the present invention is shown;

[0028] Figure 9 A schematic diagram of the structure of a first embodiment of the electric drive system according to the present invention is shown;

[0029] Figure 10 A schematic diagram of a second embodiment of the electric drive system according to the present invention is shown.

[0030] The above figures include the following reference numerals:

[0031] 1. Capacitor assembly; 11. First housing; 111. Inlet pipe; 112. Outlet pipe; 112-1. First outlet channel; 113. First water channel; 114. Second water channel; 115. Third water channel; 116. Fixing part; 117. Mounting position; 12. Water channel cover; 13. Capacitor core; 131. Input busbar; 132. Output busbar; 133. Grounding busbar; 134. Discharge resistor harness; 14. Y capacitor; 15. Filter magnetic ring; 16. Discharge resistor; 17. Potting surface;

[0032] 2. Insulation structure; 21. First component section; 22. Second component section; 23. Third component section;

[0033] 3. Power module assembly; 31. DC busbar; 32. AC busbar; 33. Power module pins;

[0034] 4. Elastic gasket;

[0035] 5. Pressure plate;

[0036] 6. Integrated three-phase busbar assembly; 61. Insulating bracket; 611. First mounting groove; 612. First through hole; 613. Mounting block; 614. Connecting block; 62. U-phase busbar; 622. Busbar bending section; 63. V-phase busbar; 64. W-phase busbar; 65. Magnetic component; 651. Second through hole; 66. First cover plate; 661. Third through hole; 67. PCB board; 671. Current sensor connector;

[0037] 7. Circuit board assembly; 71. Driver board assembly; 72. Control board assembly; 721. Signal connector;

[0038] 8. Connecting water pipes; 81. Limiting structure;

[0039] 100. Inverter assembly; 200. Second housing; 201. Sealing groove; 202. Fourth water channel; 300. Sealing block; 400. High voltage DC connector; 500. Low voltage connector; 600. Top cover; 700. Water channel sealing ring. Detailed Implementation

[0040] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0041] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0042] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such terms can be used interchangeably where appropriate so that the embodiments of this application described herein can be implemented, for example, in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0043] Exemplary embodiments according to this application will now be described in more detail with reference to the accompanying drawings. However, these exemplary embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. It should be understood that these embodiments are provided so that the disclosure of this application is thorough and complete, and that the concept of these exemplary embodiments is fully conveyed to those skilled in the art. In the drawings, for clarity, the thickness of layers and regions may be exaggerated, and the same reference numerals are used to denote the same devices, and therefore their description will be omitted.

[0044] Combination Figures 1 to 8 As shown, according to a specific embodiment of this application, an inverter assembly is provided.

[0045] Specifically, the inverter assembly includes a capacitor assembly 1, a power module assembly 3, and an integrated three-phase busbar assembly 6. The capacitor assembly 1 includes a housing assembly and an output busbar 132. A portion of the output busbar 132 is located inside the housing assembly, and the other portion of the output busbar 132 extends outside the housing assembly. The power module assembly 3 is disposed on one side of one surface of the housing assembly. A DC busbar 31 is disposed at the first end of the power module assembly 3, and multiple AC busbars 32 are disposed at the second end of the power module assembly 3. The DC busbar 31 is connected to the output busbar 132. The first end and the second end of the power module assembly 3 are disposed opposite each other along the thickness direction of the capacitor assembly 1. The integrated three-phase busbar assembly 6 includes a U-phase busbar 62, a V-phase busbar 63, and a W-phase busbar 64. Each of the U-phase busbar 62, V-phase busbar 63, and W-phase busbar 64 is connected to an AC busbar 32.

[0046] Applying the technical solution of this embodiment, the capacitor assembly 1 includes a housing assembly with an output busbar 132. The power module assembly 3 is connected to one surface of the housing assembly. The DC busbar 31 at the first end of the power module assembly 3 is connected to the output busbar 132. The AC busbars 32 at the second end of the power module assembly 3 are respectively connected to the U-phase busbar 62, V-phase busbar 63, and W-phase busbar 64 of the integrated three-phase busbar assembly 6. Furthermore, the first and second ends of the power module assembly 3 are positioned opposite each other along the thickness direction of the capacitor assembly 1, resulting in a more compact inverter assembly structure, lighter weight, and lower contact resistance, thus improving the miniaturization and integration of internal components. In this embodiment, the thickness direction of the capacitor assembly 1 is the same as the height direction of the capacitor assembly 1.

[0047] like Figure 2 , Figure 4 and Figure 5 As shown, the housing assembly includes a first housing 11 and a water channel cover 12. The first housing 11 is formed by die casting of aluminum alloy. A mounting position 117 is provided on one surface of the first housing 11. The water channel cover 12 is welded to the first housing 11, and the water channel cover 12 covers the mounting position 117, forming a first water channel 113 between the water channel cover 12 and the first housing 11. The power module assembly 3 is disposed on one side of the water channel cover 12. Specifically, the mounting position 117 is a mounting groove, and the water channel cover 12 is welded to the mounting groove by friction stir welding. The sidewall of the mounting groove facing the water channel cover 12 forms the first water channel 113. This arrangement facilitates heat dissipation for the power module assembly 3 and other heat-generating components of the capacitor assembly 1.

[0048] Furthermore, the housing assembly is also provided with a second water channel 114 and a third water channel 115, which are connected through a first water channel 113. The second water channel 114 is located at the first end of the first water channel 113, and the third water channel 115 is located at the second end of the first water channel 113. Both the second water channel 114 and the third water channel 115 extend along the width direction of the first housing 11. One end of the first housing 11 is provided with an inlet pipe 111, and the other end of the first housing 11 is provided with an outlet pipe 112. The inlet pipe 111 and the outlet pipe 112 are each connected to a connecting water pipe 8. The connecting water pipe 8 is provided with a limiting structure 81, which is arranged circumferentially along the connecting water pipe 8. An inlet channel is formed in the inlet pipe 111, and an outlet channel is formed in the outlet pipe 112. The inlet channel is connected to the second water channel 114, and the outlet channel is connected to the third water channel 115. In this embodiment, the first water channel 113, the second water channel 114, and the third water channel 115 are die-cast together with the first housing 11. The coolant enters the second water channel 114 from the water inlet channel 111 of the first housing 11, then enters the third water channel 115 through the first water channel 113, and finally flows out from the water outlet channel 112 of the first housing 11. The first water channel 113 is formed on the right side surface of the first housing 11, the second water channel 114 is formed on the front side surface of the first housing 11, and the third water channel 115 is formed on the rear side surface of the first housing 11. Thus, the first housing 11 forms a three-sided surrounding water channel, which is beneficial to improving the heat dissipation performance of the inverter assembly.

[0049] Furthermore, the housing assembly includes a first surface, a second surface, a third surface, and a fourth surface. The first surface is provided with a mounting position 117. The second and third surfaces are disposed opposite to each other and are connected to both the second and third surfaces. A second water channel 114 is formed on the second surface, and a third water channel 115 is formed on the third surface. The fourth surface is disposed opposite to the first surface and is connected to both the second and third surfaces. A fifth water channel is formed on the fourth surface. The housing assembly also includes a sixth surface, which is connected to the first, second, third, and fourth surfaces. A sixth water channel is formed on the sixth surface. The first water channel 113, the second water channel 114, the third water channel 115, the fifth water channel, and the sixth water channel are interconnected. In this embodiment, the first surface is the right side surface in the above embodiment, the second surface is the front surface in the above embodiment, and the third surface is the rear surface in the above embodiment. If the ambient temperature of the inverter assembly is higher and more severe, water channels can also be extended on the left side surface (fourth surface) and the lower surface (sixth surface) of the first housing 11. This water channel design allows the inverter assembly to adapt to different ambient temperatures. The specific number of water channels is set according to the heat dissipation needs of the inverter assembly, and the boundaries of the water channels remain basically unchanged. This enables the platform application of the inverter assembly and helps to save costs.

[0050] like Figure 2 As shown, the inverter assembly also includes a pressure plate 5 and an elastic gasket 4. The pressure plate 5 is positioned between the power module assembly 3 and the integrated three-phase busbar assembly 6, and the elastic gasket 4 is placed between the power module assembly 3 and the pressure plate 5. In this embodiment, the elastic gasket 4 provides pressure to the power module assembly 3. By calculating the pressure F required for the power module assembly 3 to overcome vibration and impact, and selecting silicone as the material for the elastic gasket 4, simulation calculations are performed based on the hardness, area, and thickness of the elastic gasket 4 to determine the minimum compression amount Δt required for the elastic gasket 4 to provide pressure F, thereby determining the distance between the pressure plate 5 and the power module assembly 3. The connection between the elastic gasket 4 and the pressure plate 5 is selected as welding or bolt connection according to process requirements. The integrated three-phase busbar assembly 6 is fixed to the pressure plate 5 by bolt connection. This arrangement further improves the integration and miniaturization of the inverter assembly and enhances the connection reliability between the power module assembly 3, the elastic gasket 4, the pressure plate 5, and the integrated three-phase busbar assembly 6.

[0051] Furthermore, the capacitor assembly 1 also includes a capacitor core 13, a Y capacitor 14, a filter magnetic ring 15, and an input busbar 131. The capacitor core 13 is disposed within the first housing 11. Multiple output buses 132 are spaced apart along the length of the first housing 11, with one end of each busbar connected to the capacitor core 13. The Y capacitor 14 is disposed within the first housing 11 and located on one side of the capacitor core 13. The filter magnetic ring 15 is also disposed within the first housing 11 and located on one side of the capacitor core 13. One end of the input busbar 131 passes through the filter magnetic ring 15 and connects to the Y capacitor, while the other end extends out of the first housing 11. Multiple input buses 131 are spaced apart along the width of the first housing 11. In this embodiment, there are two Y capacitors 14. The two Y capacitors 14 are directly encapsulated in the first housing 11 of the capacitor assembly 1, and the two Y capacitors 14 are arranged at intervals along the length of the first housing 11, thereby saving the fasteners and connectors, reducing the volume of the capacitor assembly, and thus reducing the production cost of the inverter assembly.

[0052] In another specific embodiment of this application, the capacitor assembly 1 further includes a discharge resistor 16, which is connected to the first housing 11. The position of the discharge resistor 16 is set according to the overall layout of the inverter assembly, such as being set on the left, front, or rear side of the first housing 11, thereby making full use of the space of the inverter assembly and reducing the volume of the inverter assembly. A part of the discharge resistor harness 134 is located inside the first housing 11, and another part of the discharge resistor harness 134 extends out of the first housing 11 and is plugged into the terminal of the discharge resistor 16. Using plug-in connection instead of bolt connection can improve the production cycle. Since the capacitor core 13 is generally resistant to 105℃, it is the weak point in the temperature resistance of the inverter assembly. Moreover, the capacitor core 13 is generally designed with a plastic shell. Even if the capacitor assembly 1 is cooled, it must pass through the plastic shell of the capacitor core 13. Plastic has a low thermal conductivity, so the heat dissipation effect is not obvious. Especially in hybrid vehicles, when the ambient temperature is high, the operating conditions of the inverter assembly are further limited. By setting water channels in the first shell 11 to directly cool the capacitor, and setting water channels on at least three surfaces of the first shell 11 (i.e., the first water channel 113, the second water channel 114, and the third water channel 115), heat dissipation is achieved on three sides of the capacitor assembly 1. This ensures the heat dissipation effect of heat-generating components such as the discharge resistor 16, the power module assembly 3, and the capacitor core 13, and improves the safety and flexibility of the inverter assembly.

[0053] Furthermore, the first housing 11 is provided with four fixing parts 116. Two fixing parts 116 are spaced apart from the water inlet pipe 111, and the other two fixing parts 116 are spaced apart from the water outlet pipe 112. The capacitor assembly 1 also includes a grounding busbar 133. The first end of the grounding busbar 133 is disposed inside the first housing 11 and is connected to the Y capacitor 14. The second end of the grounding busbar 133 extends out of the first housing 11 and is connected to the fixing parts 116. In this embodiment, one pin of one Y capacitor 14 is connected to the positive terminal busbar of the input busbar 131, and the other pin is connected to the grounding busbar 133; one pin of another Y capacitor 14 is connected to the negative terminal busbar of the input busbar 131, and the other pin is connected to the grounding busbar 133. The first housing 11 includes a potting surface 17. The second end of the grounding busbar 133 extends from the potting surface 17 and is connected to the fixing parts 116, thereby realizing the grounding function.

[0054] Furthermore, the inverter assembly also includes a circuit board assembly 7, which is connected to the first housing 11. The circuit board assembly 7 includes a drive board assembly 71 and a control board assembly 72, which are integrally formed. The drive board assembly 71 is located at the bottom of the first housing 11, and the control board assembly 72 extends along the height direction of the first housing 11. The control board assembly 72 is provided with a signal connector 721. In this embodiment, the control board assembly 72 is located on the left side surface of the first housing 11, and the drive board assembly 71 and the control board assembly 72 form an L-shaped structure. By integrating the drive board assembly 71 and the control board assembly 72, the wiring harness connections between them are reduced, which further helps to reduce the production cost of the inverter assembly, shrink the size of the inverter assembly, and improve the production cycle of the inverter assembly. Moreover, the circuit board assembly 7 adopts a flexible PCB design, which can utilize space that is not on the same plane, making the layout more flexible and the space utilization rate higher.

[0055] In one exemplary embodiment of this application, a plurality of power module pins 33 are further provided at the second end of the power module assembly. The power module pins 33 and the AC busbar 32 are spaced apart along the length of the power module assembly. The power module pins 33 are connected to the drive board assembly 71 of the circuit board assembly 7. The drive board assembly 71 is fixed to the bottom of the first housing 11 by bolts, and the control board assembly 72 is fixed to the left side surface of the first housing 11 by bolts.

[0056] In this design, the DC busbar 31 at the first end of the power module assembly 3 is connected to the output busbar 132 via laser welding. Similarly, the AC busbars 32 at the second end of the power module assembly 3 are also connected to the U-phase busbar 62, V-phase busbar 63, and W-phase busbar 64 of the integrated three-phase busbar assembly 6 via laser welding. Using laser welding technology instead of bolt connections allows for a more compact, lighter, and less resistant inverter assembly. The inverter assembly of this application is centered around the capacitor assembly 1, with other components arranged around it. Laser welding technology is used to integrate the inverter assembly into a single unit, achieving miniaturization and integration of the inverter assembly, and providing high flexibility in its layout.

[0057] like Figure 3 and Figure 6As shown, the integrated three-phase busbar assembly 6 includes an insulating support 61, and multiple connecting components are spaced apart along the length of the insulating support 61. The multiple connecting components are respectively used for the U-phase busbar 62, V-phase busbar 63 and W-phase busbar 64 to pass through and connect to the insulating support 61. At least one connecting component includes a mounting block 613, a magnetic element 65, and a first cover plate 66. A connecting block 614 is disposed in the center of the mounting block 613, and a first through hole 612 is formed in the center of the connecting block 614. A first mounting groove 611 is formed between the outer wall surface of the connecting block 614 and the inner wall surface of the mounting block 613. A magnetic element 65 is disposed within the first mounting groove 611, and a second through hole 651 is formed in the center of the magnetic element 65. The connecting block 614 is located within the second through hole 651. The first cover plate 66 is connected to the magnetic element 65, and a third through hole 661 is formed in the center of the first cover plate 66. The third through hole 661 communicates with the first through hole 612 to form a clearance channel for the U-phase busbar 62, V-phase busbar 63, or W-phase busbar 64 to pass through. Specifically, there are three connecting components, each corresponding to one of the U-phase busbar 62, V-phase busbar 63, and W-phase busbar 64. By applying adhesive to the first mounting groove 611, the magnetic element 65 is placed inside the first mounting groove 611, and then the first cover plate 66 is fastened onto the magnetic element 65. The first cover plate 66 and the groove wall of the first mounting groove 611 are then welded together using ultrasonic welding, thereby forming a mounting assembly. As an alternative embodiment, the first cover plate 66 and the first mounting groove 611 can also be connected by a snap-fit ​​fixing method, such as... Figure 7 As shown. Wherein, after one end of the U-phase busbar 62, V-phase busbar 63, or W-phase busbar 64 passes through the clearance passage, one end of the U-phase busbar 62, V-phase busbar 63, or W-phase busbar 64 is bent to form a busbar bending section 622, as shown. Figure 6 Then, connect one end of the U-phase busbar 62, V-phase busbar 63, or W-phase busbar 64 to an AC busbar 32. Alternatively, after one end of the U-phase busbar 62, V-phase busbar 63, or W-phase busbar 64 passes through the clearance passage, instead of bending one end of the U-phase busbar 62, V-phase busbar 63, or W-phase busbar 64, bend the three AC busbars 32 twice, and then connect the three AC busbars 32 to one end of the U-phase busbar 62, V-phase busbar 63, and W-phase busbar 64 respectively.

[0058] In another specific embodiment of this application, the connection component can also be configured as having only one first cover plate 66. Specifically, by lengthening the first cover plate 66 and opening three third through holes 661 at intervals along the length direction of the first cover plate 66, and then communicating with the first through hole 612 through the third through holes 661 to form a clearance channel for the U-phase busbar 62, V-phase busbar 63 or W-phase busbar 64 to pass through, the connection between the U-phase busbar 62, V-phase busbar 63 or W-phase busbar 64 and the AC busbar 32 can also be completed.

[0059] Furthermore, the integrated three-phase busbar assembly 6 also includes a PCB board 67, which is located at the bottom of the insulating bracket 61 and on one side of the mounting block 613. The PCB board 67 is equipped with a current sensor connector 671, which connects to the drive board assembly 71. This arrangement integrates the current sensor with the integrated three-phase busbar assembly 6. Compared to a packaged, independent current sensor, this results in a lower cost, more flexible layout, and smaller size for the inverter assembly.

[0060] like Figure 2 The inverter assembly also includes an insulation structure 2, which is connected to the housing assembly. The insulation structure 2 includes a first section 21, a second section 22, and a third section 23. The second section 22 is located within a limiting space. The second section 22 and the third section 23 are arranged opposite to each other and are connected through the first section 21. A first limiting space is formed between the second section 22 and the third section 23. Part of the water channel cover 12 is located within the first limiting space. The first section 21 is located between the power module assembly 3 and the water channel cover 12. Specifically, the first housing 11 is made of aluminum alloy. The first section 21 is attached to the surface with the largest area of ​​the water channel cover 12. The second section 22 is attached to the upper side of the first housing 11, and the third section 23 is attached to the lower side of the first housing 11. The power module assembly 3 is placed side by side on the insulation structure 2. This arrangement avoids insufficient electrical clearance and creepage distance between the DC busbar and AC busbar of the power module assembly 3 and the first housing 11.

[0061] According to another specific embodiment of this application, an electric drive system is provided, such as... Figure 9 and Figure 10 The electric drive system includes an inverter assembly 100, which is the inverter assembly described in the above embodiment. The electric drive system also includes a second housing 200, which has a receiving cavity. A portion of the inverter assembly 100 is disposed within the receiving cavity. The second housing 200 has a sealing groove 201, and a sealing block 300 is disposed within the sealing groove 201. A connecting water pipe 8 extends out of the second housing 200 through the sealing block 300, and the sealing block 300 abuts against a limiting structure 81. By assembling the inverter assembly 100 into the receiving cavity of the second housing 200, a three-in-one or multi-in-one electric drive system is formed, and the sealing block achieves a dry cavity seal between the inverter assembly and the second housing 200. In this embodiment, because the electric drive system uses the inverter assembly described in the above embodiment, the inverter assembly structure is more compact and miniaturized, resulting in more flexible arrangement of the inverter assembly in the electric drive system and saving space in the electric drive system.

[0062] Furthermore, the electric drive system also includes a top cover 600, a high-voltage DC connector 400, and a low-voltage connector 500. The top cover 600 is connected to the second housing 200, and the high-voltage DC connector 400 is connected to the input busbar 131. Specifically, the shape of the input busbar 131 is adjusted according to the arrangement direction of the high-voltage DC connector 400. The low-voltage connector 500 is connected to the signal connector 721. The second housing 200 contains a fourth water channel 202, and the first housing 11 contains a first water outlet channel 112-1. The fourth water channel 202 communicates with the water outlet channel through the first water outlet channel 112-1. A water channel sealing ring 700 is provided on the outer ring of the second housing 200 around the fourth water channel 202, and a portion of the water channel sealing ring 700 abuts against the first housing 11. The top cover 600 further achieves a dry cavity seal between the inverter assembly and the second housing 200, and the fourth water channel 202 within the second housing 200 further ensures effective heat dissipation for the inverter assembly. As an alternative embodiment, the inverter assembly water channels can also be designed independently without being connected to the fourth water channel 202.

[0063] According to another specific embodiment of this application, a vehicle is provided, including an electric drive system, which is the electric drive system described in the above embodiments. Because the vehicle uses the electric drive system described in the above embodiments, which includes the inverter assembly described in the above embodiments, the inverter assembly has better heat dissipation performance, smaller size, and more flexible arrangement, thereby helping to save vehicle space and improve vehicle performance.

[0064] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0065] In addition to the above, it should be noted that the terms "one embodiment," "another embodiment," and "embodiment" used in this specification refer to specific features, structures, or characteristics described in connection with that embodiment, which are included in at least one embodiment described in the general description of this application. The appearance of the same expression in multiple places in the specification does not necessarily refer to the same embodiment. Furthermore, when a specific feature, structure, or characteristic is described in connection with any embodiment, the intention is to suggest that implementing such a feature, structure, or characteristic in conjunction with other embodiments also falls within the scope of this invention.

[0066] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0067] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An inverter assembly, characterized in that, include: A capacitor assembly (1) includes a housing assembly and an output busbar (132), a portion of which is located within the housing assembly and another portion of which extends outside the housing assembly; A power module assembly (3) is disposed on one side of one surface of the housing assembly. A DC busbar (31) is disposed at the first end of the power module assembly (3), and a plurality of AC busbars (32) are disposed at the second end of the power module assembly (3). The DC busbar (31) and the output busbar (132) are connected by welding. The first end and the second end of the power module assembly (3) are disposed opposite to each other along the thickness direction of the capacitor assembly (1). An integrated three-phase busbar assembly (6) includes a U-phase busbar (62), a V-phase busbar (63), and a W-phase busbar (64), each of which is connected to an AC busbar (32). The housing assembly includes a first housing (11); The circuit board assembly (7) is connected to the first housing (11). The circuit board assembly (7) includes a drive board assembly (71) and a control board assembly (72). The drive board assembly (71) and the control board assembly (72) are integrally formed. The drive board assembly (71) is located at the bottom of the first housing (11). The control board assembly (72) extends along the height direction of the first housing (11). The control board assembly (72) is provided with a signal connector (721).

2. The inverter assembly according to claim 1, characterized in that, The housing assembly includes: The first housing (11) is formed by die casting of aluminum alloy, and a mounting position (117) is provided on one surface of the first housing (11). Waterway cover plate (12), the waterway cover plate (12) is welded to the first housing (11), and the waterway cover plate (12) is placed on the mounting position (117). A first waterway (113) is formed between the waterway cover plate (12) and the first housing (11). The power module assembly (3) is disposed on one side of the waterway cover plate (12).

3. The inverter assembly according to claim 2, characterized in that, The housing assembly is further provided with a second water channel (114) and a third water channel (115), which are connected through the first water channel (113). The second water channel (114) is located at the first end of the first water channel (113), and the third water channel (115) is located at the second end of the first water channel (113). Both the second water channel (114) and the third water channel (115) extend along the width direction of the first housing (11). One end of the first housing (11) is provided with a water inlet pipe (111), and the other end of the first housing (11) is provided with a water outlet pipe (112). The water inlet pipe (111) and the water outlet pipe (112) are each connected to a connecting water pipe (8). The connecting water pipe (8) is provided with a limiting structure (81). The limiting structure (81) is arranged along the circumference of the connecting water pipe (8). A water inlet channel is formed in the water inlet pipe (111), and a water outlet channel is formed in the water outlet pipe (112). The water inlet channel is connected to the second water channel (114), and the water outlet channel is connected to the third water channel (115).

4. The inverter assembly according to claim 3, characterized in that, The housing assembly includes a first surface, a second surface, a third surface, and a fourth surface. The first surface is provided with the mounting position (117). The second surface and the third surface are disposed opposite to each other and are connected to both the second and third surfaces. A second water channel (114) is formed on the second surface, and a third water channel (115) is formed on the third surface. The fourth surface is disposed opposite to the first surface and is connected to both the second and third surfaces. A fifth water channel is formed on the fourth surface. The housing assembly also includes a sixth surface, which is connected to the first, second, third, and fourth surfaces. A sixth water channel is formed on the sixth surface. The first water channel (113), the second water channel (114), the third water channel (115), the fifth water channel, and the sixth water channel are interconnected.

5. The inverter assembly according to claim 1, characterized in that, The inverter assembly also includes: Pressure plate (5), the pressure plate (5) is disposed between the power module assembly (3) and the integrated three-phase busbar assembly (6); An elastic gasket (4) is placed between the power module assembly (3) and the pressure plate (5).

6. The inverter assembly according to claim 3, characterized in that, The capacitor assembly (1) also includes: A capacitor core (13) is disposed inside the first housing (11). There are multiple output busbars (132), which are spaced apart along the length of the first housing (11). One end of the output busbar (132) is connected to the capacitor core (13). Y capacitor (14), the Y capacitor (14) is disposed inside the first housing (11), and the Y capacitor (14) is located on one side of the capacitor core (13); A filter magnetic ring (15) is disposed inside the first housing (11) and is located on one side of the capacitor core (13); An input busbar (131) is provided, one end of which passes through the filter magnetic ring (15) and is connected to the Y capacitor (14). The other end of the input busbar (131) extends out of the first housing (11). There are multiple input busbars (131), and the multiple input busbars (131) are arranged at intervals along the width direction of the first housing (11).

7. The inverter assembly according to claim 6, characterized in that, The first housing (11) is provided with four fixing parts (116). Two of the fixing parts (116) are arranged at intervals with the water inlet pipe (111), and the other two fixing parts (116) are arranged at intervals with the water outlet pipe (112). The capacitor assembly (1) also includes a ground busbar (133). The first end of the ground busbar (133) is located inside the first housing (11) and is connected to the Y capacitor (14). The second end of the ground busbar (133) extends out of the first housing (11) and is connected to the fixing parts (116).

8. The inverter assembly according to claim 2, characterized in that, The integrated three-phase busbar assembly (6) includes an insulating bracket (61), and a plurality of connecting components are spaced apart along the length of the insulating bracket (61). The plurality of connecting components are respectively used for the U-phase busbar (62), the V-phase busbar (63), and the W-phase busbar (64) to pass through and connect to the insulating bracket (61), wherein at least one of the connecting components includes: Mounting block (613), the middle of which is provided with connecting block (614), the middle of which is provided with first through hole (612), and the outer wall surface of connecting block (614) and the inner wall surface of mounting block (613) form a first mounting groove (611). A magnetic element (65) is provided in the first mounting groove (611), and a second through hole (651) is provided in the middle of the magnetic element (65), and the connecting block (614) is located in the second through hole (651). A first cover plate (66) is connected to the magnetic element (65). A third through hole (661) is provided in the middle of the first cover plate (66). The third through hole (661) communicates with the first through hole (612) to form a clearance channel for the U-phase busbar (62), the V-phase busbar (63) or the W-phase busbar (64) to pass through.

9. The inverter assembly according to claim 8, characterized in that, The integrated three-phase busbar assembly (6) also includes: PCB board (67) is disposed at the bottom of the insulating bracket (61) and is located on one side of the mounting block (613). The PCB board (67) is provided with a current sensor connector (671) and the current sensor connector (671) is connected to the drive board assembly (71).

10. The inverter assembly according to claim 2, characterized in that, The inverter assembly also includes: An insulating structure (2) is connected to the housing assembly. The insulating structure (2) includes a first component segment (21), a second component segment (22), and a third component segment (23). The second component segment (22) and the third component segment (23) are arranged opposite to each other and are connected through the first component segment (21). A first limiting space is formed between the second component segment (22) and the third component segment (23). A portion of the water channel cover (12) is located within the first limiting space. The first component segment (21) is located between the power module assembly (3) and the water channel cover (12).

11. An electric drive system, characterized in that, The system includes an inverter assembly (100), which is the inverter assembly according to any one of claims 1-10. The electric drive system also includes a second housing (200), which has a receiving cavity. A portion of the inverter assembly (100) is disposed in the receiving cavity. The second housing (200) has a sealing groove (201). A sealing block (300) is disposed in the sealing groove (201). A connecting water pipe (8) extends out of the second housing (200) through the sealing block (300), and the sealing block (300) abuts against the limiting structure (81).

12. The electric drive system according to claim 11, characterized in that, The electric drive system also includes: A top cover (600) is connected to the second housing (200); A high-voltage DC connector (400) is connected to an input busbar (131); A low-voltage connector (500) is connected to a signal connector (721); The second housing (200) is provided with a fourth water channel (202), and the first housing (11) is provided with a first water outlet channel (112-1). The fourth water channel (202) is connected to the water outlet channel through the first water outlet channel (112-1). The second housing (200) is provided with a water channel sealing ring (700) on the outer ring of the fourth water channel (202), and a portion of the water channel sealing ring (700) abuts against the first housing (11).

13. A vehicle, characterized in that, Includes an electric drive system, wherein the electric drive system is the electric drive system as described in claim 11 or 12.

Images