A motor controller integrated with high and low voltage charging functions

Abstract

The application relates to a motor controller integrated with high and low voltage charging functions, which comprises a first relay, a second relay, an IGBT assembly, a four-phase output assembly, a direct current charging plug-in and a power taking plug-in; the direct current charging plug-in is connected with a first relay input end of the first relay and a second relay input end of the second relay; the four-phase output assembly comprises a three-phase input end, a three-phase output end, a neutral input end and a neutral output end, the IGBT assembly output end is connected with the three-phase input end, a second relay output end of the second relay is connected with the neutral input end, a first relay output end of the first relay is connected with the power taking plug-in, the three-phase output end and the neutral output end are connected with a motor, and the IGBT assembly is connected with the power taking plug-in; and the power taking plug-in is connected with a battery. Compared with the prior art, the application has the advantages of being compatible with high and low voltage charging piles, being capable of using domestic alternating current and the like.

Description

Technical Field

[0001] This invention relates to the field of electric vehicle charging, and in particular to a motor controller that integrates high and low voltage charging functions. Background Technology

[0002] In recent years, with the depletion of fossil fuels and the increasing prominence of environmental pollution worldwide, new energy vehicles have gained recognition from governments and organizations around the world due to their "green" and "low-emission" characteristics. Currently, new energy electric vehicles account for half of all traditional gasoline-powered vehicles. However, the energy storage devices of electric vehicles heavily rely on onboard batteries, and for a long time, the development of battery energy storage technology will struggle to make charging as convenient and quick as refueling a traditional gasoline vehicle. At the same time, the number of electric vehicle charging stations in China is extremely limited compared to traditional gas stations, and this inconvenience contributes to range anxiety for drivers and passengers. Existing motor controllers are incompatible with high- and low-voltage charging piles and household AC charging methods. If a charging station only has one type of charging pile, it may encounter charging incompatibility issues, causing inconvenience to electric vehicle users. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the prior art and provide a motor controller that integrates high and low voltage charging functions.

[0004] The objective of this invention can be achieved through the following technical solutions: A motor controller integrating high and low voltage charging functions includes a first relay, a second relay, an IGBT assembly, a four-phase output assembly, a DC charging plug-in, and a power supply plug-in. The DC charging plug-in is connected to the first relay input terminal of the first relay and the second relay input terminal of the second relay. The four-phase output assembly includes a three-phase input terminal, a three-phase output terminal, a neutral input terminal, and a neutral output terminal. The output terminal of the IGBT assembly is connected to the three-phase input terminal. The second relay output terminal of the second relay is connected to the neutral input terminal. The first relay output terminal of the first relay is connected to the power supply plug-in. The three-phase output terminal and the neutral output terminal are connected to the motor. The IGBT assembly is connected to the power supply plug-in. The power supply plug-in is connected to a battery.

[0005] Furthermore, when the controller is operating in charging mode: When the DC plug is connected to a high-voltage charging pile, the first relay is activated and the second relay is deactivated, and the high-voltage charging pile directly supplies power to the battery through the first relay; when the motor controller is connected to a low-voltage charging pile, the second relay is activated and the first relay is deactivated, and the low voltage enters the four-phase output component through the second relay, and is then boosted by the boost circuit composed of the IGBT component and the motor, and the boosted voltage supplies power to the battery through the IGBT component. When the controller is operating in motor drive mode: The battery supplies power to the IGBT component through a power input plug, which drives the motor to rotate.

[0006] Furthermore, it also includes a DC-DC / OBC integrated component, an AC charging plug-in, and a single-ended plug-in. One end of the DC-DC / OBC integrated component is provided with a power harness, a DC-DC output terminal, and an OBC charging terminal. The AC plug-in is connected to the OBC charging terminal, and the DC-DC output terminal is connected to the single-ended plug-in.

[0007] Furthermore, it also includes a first EMC component and a second EMC component. The first EMC component includes a first positive input terminal and a first negative input terminal, and the second EMC component includes a third positive input terminal and a third negative input terminal. The first positive input terminal and the first negative input terminal are connected to a power supply plug-in, and the third positive input terminal and the third negative input terminal are connected to a DC charging plug-in.

[0008] Furthermore, the first EMC component also includes a support capacitor, and the second EMC component also includes a magnetic ring. The first EMC component is used for current filtering in motor drive mode, and the second EMC component is used for current filtering in charging mode.

[0009] Furthermore, it also includes a filter component, the input of which is connected to the DC charging plug-in, and the output of which is connected to the second EMC component.

[0010] Furthermore, it also includes a housing, in which the first relay, the second relay, the IGBT assembly, and the four-phase output assembly are all housed. A heat-conducting platform is provided inside the housing, and a first support column is provided on one side of the heat-conducting platform. The first EMC assembly is fixed on the first support column.

[0011] Furthermore, it also includes a PDU plug-in, which is connected to the first EMC component.

[0012] Furthermore, it also includes a first adapter component and a second adapter component, wherein the first relay output terminal of the first relay is connected to the first EMC component through the first adapter component, and the second relay output terminal of the second relay is connected to the second EMC component through the second adapter component.

[0013] Furthermore, a three-phase current sensor is provided on the four-phase output component.

[0014] Compared with the prior art, the present invention has the following advantages: 1. This invention incorporates a first relay, a second relay, a four-phase output component, an IGBT component, and a motor. Different relays operate when charging piles of different voltages are connected to the controller. At high voltage, the battery is directly connected; at low voltage, the four-phase output component connects to a boost circuit composed of the IGBT component and the motor, achieving a boost function. This design is compatible with both high and low voltage charging piles, solving the problem of inconvenient charging in existing controllers. Furthermore, this invention does not use a BOOST inductor as the boost component, saving space and facilitating the integration of other functional components.

[0015] 2. The present invention also includes a DC-DC / OBC integrated component, wherein the DC-DC part is used to supply power to the load, and the OBC part is provided with a charging terminal, which can also achieve the charging effect when the mains power is connected to the controller, further improving compatibility and practicality.

[0016] 3. The present invention includes a first EMC component, a second EMC component, and a filtering component, which ensures the electromagnetic compatibility of the controller when driving the motor and during charging, and also reduces electromagnetic noise. Attached Figure Description

[0017] Figure 1 This is an exploded view of the structure of the present invention.

[0018] Figure 2 This is a schematic diagram of the motor controller housing of the present invention.

[0019] Figure 3 This is a schematic diagram of the lower cavity of the motor controller housing of the present invention.

[0020] Figure 4 This is a schematic diagram of the structure of the integrated four-phase output component of the present invention. Figure 5 This is a schematic diagram of the structure of the first EMC component integration component of the present invention.

[0021] Figure 6 This is a schematic diagram of the structure of the second EMC component integration component of the present invention.

[0022] Figure 7 This is a schematic diagram of the integrated filter component of the present invention.

[0023] Figure 8 This is a schematic diagram of the structure of the first adapter component integrated component of the present invention.

[0024] Figure 9 This is a schematic diagram of the structure of the second adapter component integrated component of the present invention.

[0025] Figure 10 This is a schematic diagram of the structure of the DC-DC / OBC integrated component of the present invention.

[0026] Reference numerals: 1-Box, 2-First EMC component, 3-Second EMC component, 4-Filter component, 5-First adapter component, 6-Second adapter component, 7-Four-phase output component, 8-DC / OBC integrated component, 12-IGBT component, 13-Power supply plug, 14-DC charging plug, 15-AC charging plug, 16-PDU plug, 17-Single-way plug, 18-Lower cavity, 181-Rectangular opening, 182-Fixing hole, Q1-First relay, Q2-Second relay, 111-Heat conduction platform, 112-First support, 113-Second support, 114-Third support, 115-Fourth support, 116-Fifth support, 117-Four-phase port, 118-Sixth support Column, Q11-First relay input terminal, Q12-First relay output terminal, Q21-Second relay input terminal, Q22-Second relay output terminal, 21-Pre-amplifier assembly, 22-Support capacitor, 21A-First positive input terminal, 21B-First negative input terminal, 211-Main magnetic ring, 212-Secondary magnetic ring, 213-PDU fuse, 214-PDU copper busbar, 221-Capacitor output terminal, 22A-Second positive input terminal; 22B-Second negative input terminal, 31-First-order magnetic ring, 32-Second-order magnetic ring, 3 A1 - Third positive input terminal, 3B1 - Third negative input terminal, 3A2 - Third positive main output terminal, 3B2 - Third negative output terminal, 3A3 - Third positive secondary output terminal, 41 - Filter capacitor, 4A - Positive filter copper busbar, 4B - Negative filter copper busbar, 4A1 - Positive copper busbar input terminal, 4B1 - Negative copper busbar input terminal, 4A2 - Positive filter hole, 4B2 - Negative filter hole, 4A3 - Positive copper busbar output terminal, 4B3 - Negative copper busbar output terminal, 51 - First adapter support, 5A - First adapter positive terminal Copper busbar, 5B-First adapter negative copper busbar, 5A1-First adapter positive input terminal, 5B1-First adapter negative input terminal, 5A2-First adapter positive output terminal, 5B2-First adapter negative output terminal, 61-Second adapter input terminal, 62-Second adapter output terminal, 71-Output support, 72-Three-phase current sensor, 73-Three-phase input terminal, R1-Neutral input terminal, 74-Three-phase output terminal, R2-Neutral output terminal, 81-Power harness, 82-DC-CDC output terminal, 83-OBC charging terminal. Detailed Implementation

[0027] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. These embodiments are based on the technical solution of the present invention and provide detailed implementation methods and specific operating procedures. However, the scope of protection of the present invention is not limited to the following embodiments.

[0028] This embodiment provides a motor controller that integrates high and low voltage charging functions, such as... Figure 1 and Figure 2As shown, the enclosure includes a housing 1, a first relay Q1, a second relay Q2, an IGBT assembly 12, a four-phase output assembly 7, a power supply plug 13, a DC charging plug 14, an AC charging plug 15, a PDU plug, a first adapter assembly 5, a second adapter assembly 6, a first EMC assembly 2, a second EMC assembly 3, a filter assembly 4, and a DC-DC / OBC integrated assembly 8. The first relay Q1, the second relay Q2, the IGBT assembly 12, the four-phase output assembly 7, the first adapter assembly 5, the second adapter assembly 6, the first EMC assembly 2, the second EMC assembly 3, the filter assembly 4, and the DC-DC / OBC integrated assembly 8 are all housed inside the housing 1, while the PDU plug, the power supply plug 13, the DC charging plug 14, and the AC charging plug 15 are located on the outer surface of the housing 1.

[0029] Specifically, a heat-conducting platform 111 is provided inside the housing 1. A waist-shaped first support column 112 is provided on one side of the heat-conducting platform 111 for fixing the first EMC component 2. Three cylindrical second support columns 113 are provided on the side of the housing 1 near the DC charging plug 14 for fixing the filter component 4. A third support column 114, a fourth support column 115, and a fifth support column 116 are provided on the other side of the housing 1 for installing the second EMC component 3, the first adapter component 5, and the second adapter component 6, respectively. A four-phase port 117 is provided on one side of the IGBT component 12, and a sixth support column 118 is provided on one side of the four-phase port 117 for fixing the four-phase output component 7. A cavity 18 exists at the bottom of the housing 1, such as... Figure 3 As shown, a rectangular opening 181 and multiple fixing holes 182 are provided. The multiple fixing holes 182 are used to install the DC-DC / OBC integrated assembly 8 in the lower cavity 18.

[0030] The first relay Q1 is provided with a first relay input terminal Q11 and a first relay output terminal Q12, the second relay Q2 is provided with a second relay input terminal Q21 and a second relay output terminal Q22, a four-phase port 117 is provided on one side of the IGBT assembly 12, and the four-phase output assembly 7 passes through the four-phase port 117 and is fixed on the first support 112.

[0031] Four-phase output component 7, etc. Figure 4 As shown, it consists of a base 71, a three-phase input terminal 73, a three-phase output terminal 74, a neutral input terminal R1, and a neutral output terminal R2. The three-phase current sensor 72 has its three-phase input terminal 73 and three-phase output terminal 74 located at the upper and lower ends of the base 71, respectively, and its neutral input terminal R1 and neutral output terminal R2 located at the upper and lower ends of the base 71, respectively.

[0032] First EMC component 2, as shown Figure 5As shown, the device includes a pre-amplifier 21 and a support capacitor 22. The pre-amplifier 21 integrates a main magnetic ring 211, a secondary magnetic ring 212, a PDU fuse 213, and a PDU copper busbar 214. The pre-amplifier 21 also integrates multiple positive and negative plates. One end of each positive and negative plate is provided with a first positive input terminal 21A and a first negative input terminal 21B. The other end of the positive and negative plates passes through the main magnetic ring 211 and the secondary magnetic ring 212 and is electrically connected to the support capacitor. The support capacitor 22 includes six alternating positive and negative capacitor output terminals 221. Near the capacitor output terminals 221, a set of stacked second positive input terminals 22A and second negative input terminals 22B are provided.

[0033] The second EMC component 3, as shown in Figure 6 As shown, it includes a first-order magnetic ring 31, a second-order magnetic ring 32 and a set of positive and negative busbars. One end of the second EMC component 3 is provided with a third positive input terminal 3A1 and a third negative input terminal 3B1, and the other end is provided with a third positive main output terminal 3A2, a third negative output terminal 3B2 and a third positive secondary output terminal 3A3.

[0034] Filter component 4, such as Figure 7 As shown, the system includes a positive filter copper busbar 4A, a negative filter copper busbar 4B, and a filter capacitor 41. Positive filter holes 4A2 and negative filter holes 4B2 are located between the positive and negative filter copper busbars 4A and 4B, respectively. Positive filter copper busbar 4A has a positive input terminal 4A1 and a positive output terminal 4A3 at its two ends, and negative filter copper busbar 4B has a negative input terminal 4B1 and a negative output terminal 4B3 at its two ends. The terminals of the filter capacitor are electrically connected to the positive filter holes 4A2 and 4B2 via bolts.

[0035] First adapter component 5, as shown Figure 8 As shown, it includes a first adapter support 51, a first adapter positive copper busbar 5A and a first adapter negative copper busbar 5B. The first adapter positive copper busbar 5A has a first adapter positive input terminal 5A1 and a first adapter positive output terminal 5A2 respectively at both ends. The first adapter negative copper busbar 5B has a first adapter negative input terminal 5B1 and a first adapter negative output terminal 5B2 respectively at both ends.

[0036] Second adapter component 6, as shown Figure 9 As shown, a second adapter input terminal 61 and a second adapter output terminal 62 are respectively provided at both ends.

[0037] DCDC / OBC integrated components 8 such as Figure 10 As shown, it has a cuboid structure, with a power harness 81, a DC-DC output terminal 82 and an OBC charging terminal 83 at one end.

[0038] The specific connection relationships of the motor controller are as follows: The power supply plug 13 is electrically connected to the first positive input terminal 21A and the first negative input terminal 21B of the first EMC component 2. The first EMC component 2 is electrically connected to the input terminal of the power IGBT 12 through the capacitor output terminal 221. The output terminal of the IGBT component 12 is electrically connected to the three-phase input terminal 73 of the four-phase output component 7.

[0039] The DC charging plug 14 is electrically connected to the positive copper busbar input terminal 4A1 and the negative copper busbar input terminal 4B1 of the filter component 4. The positive copper busbar output terminal 4A3 and the negative copper busbar output terminal 4B3 of the filter component 44 are electrically connected to the third positive input terminal 3A1 and the third negative input terminal 3B1 of the second EMC component 33, respectively. The third negative output terminal 3B2 of the second EMC component 33 is electrically connected to the second negative input terminal 22B of the first EMC component 2. The third positive secondary output terminal 3A3 of the second EMC component 3 is electrically connected to the first relay input terminal Q11 of the first relay Q1. The first relay output terminal Q12 of the first relay Q1 is electrically connected to the first adapter positive input terminal 5A1 of the first adapter component 55. The first adapter positive copper busbar 5A is electrically connected to the second positive input terminal 22A of the first EMC component 2 through the first adapter positive output terminal 5A2.

[0040] The third positive main circuit output terminal 3A2 of the second EMC component 3 is electrically connected to the second relay input terminal Q21 of the second relay Q2, the second relay output terminal Q22 of the second relay Q2 is electrically connected to the second transfer input terminal 61 of the second transfer component 6, and the second transfer output terminal of the second transfer component 6 is connected to the neutral input terminal R1 of the four-phase output component 77.

[0041] The positive and negative terminals inside the PDU plug-in 16 are electrically connected to the PDU copper busbar 214 and the first negative input terminal 21B of the first EMC component 2, respectively. The PDU plug-in 16 is used to supply power to the vehicle load.

[0042] The AC charging plug 15 is electrically connected to the OBC charging terminal 83 of the DC-DC / OBC integrated component 8 via an internal wiring harness passing through the rectangular opening 181 of the housing 1. The single-path plug 17 is electrically connected to the DC-DC output terminal 82 of the DC-DC / OBC integrated component 8 via a wiring harness. The power wiring harness 81 of the DC-DC / OBC integrated component 8 is electrically connected to the first positive input terminal 21A and the first negative input terminal 21B of the first EMC component 22.

[0043] After assembly, connect the four-phase output component 7 to the motor. The specific workflow is as follows: When in charging mode: When the DC charging plug 14 is connected to the high-voltage platform charging pile, the first relay Q1 closes and the second relay Q2 opens, and the DC power directly charges the two ends of the battery through the power taking plug 13.

[0044] When the DC charging plug 14 is connected to the low-voltage platform charging pile, the first relay Q1 is open and the second relay Q2 is closed. The DC positive potential reaches the neutral input terminal R1 through the second relay Q2, and is boosted by the BOOST boost circuit composed of the motor and IGBT. Thus, a high potential voltage is output to the positive terminal of the battery for charging through the IGBT component 12 and the power extraction plug 13.

[0045] When the AC charging plug-in 15 is connected to AC mains power, the DC output terminal 82 in the DC-DC / OBC integrated component 8 is stepped down and DC high voltage is input to the positive and negative terminals of the power battery through the OBC charging terminal 83 for energy storage charging.

[0046] When in charging mode, according to the connection relationship, the second EMC component 3 works to filter the charging current.

[0047] When in motor drive mode: The battery supplies power to the motor controller through the power take-off plug 13.

[0048] When in motor drive mode, according to the connection relationship, the first EMC component 2 works to filter the current supplied by the battery.

[0049] The preferred embodiments of the present invention have been described in detail above. It should be understood that those skilled in the art can make numerous modifications and variations based on the concept of the present invention without creative effort. Therefore, all technical solutions that can be obtained by those skilled in the art based on the concept of the present invention through logical analysis, reasoning, or limited experimentation on the basis of existing technology should be within the scope of protection defined by the claims.

[0050] Thus, a highly integrated motor controller with high and low voltage charging functions can achieve the expected functions.

Claims

1. A motor controller integrating high and low voltage charging functions, characterized in that, It includes a first relay (Q1), a second relay (Q2), an IGBT assembly (12), a four-phase output assembly (7), a DC charging plug-in (14), and a power supply plug-in (13). The DC charging plug (14) is connected to the first relay input terminal (Q11) of the first relay (Q1) and the second relay input terminal (Q21) of the second relay (Q2). The four-phase output component (7) includes a three-phase input terminal (73), a three-phase output terminal (74), a neutral input terminal (R1), and a neutral output terminal (R2). The output terminal of the IGBT component (12) is connected to the three-phase input terminal (73). The second relay output terminal (Q22) of the second relay (Q2) is connected to the neutral input terminal (R1). The first relay output terminal (Q12) of the first relay (Q1) is connected to the power-taking plug (13). The three-phase output terminal (74) and the neutral output terminal (R2) are connected to the motor. The IGBT component (12) is connected to the power-taking plug (13). The power-taking plug (13) is connected to the battery. When the controller is operating in charging mode: When the DC charging plug (14) is connected to the high-voltage charging pile, the first relay (Q1) is working and the second relay (Q2) is disconnected. The high-voltage charging pile directly supplies power to the battery through the first relay (Q1). When the DC charging plug (14) is connected to the low-voltage charging pile, the second relay (Q2) is working and the first relay (Q1) is disconnected. The low voltage enters the four-phase output component (7) through the second relay (Q2), and is then boosted by the boost circuit composed of the IGBT component (12) and the motor. The boosted voltage is then supplied to the battery through the IGBT component (12). When the controller is operating in motor drive mode: The battery supplies power to the IGBT assembly (12) through the power take-off plug (13), which drives the motor to rotate.

2. A motor controller integrating high and low voltage charging functions according to claim 1, characterized in that, It also includes a DC-DC / OBC integrated component (8), an AC charging plug (15), and a single-pass plug (17). One end of the DC-DC / OBC integrated component (8) is provided with a power harness (81), a DC-DC output terminal (82), and an OBC charging terminal (83). The AC charging plug (15) is connected to the OBC charging terminal (83), and the DC-DC output terminal (82) is connected to the single-pass plug (17).

3. A motor controller integrating high and low voltage charging functions according to claim 1, characterized in that, It also includes a first EMC component (2) and a second EMC component (3). The first EMC component (2) includes a first positive input terminal (21A) and a first negative input terminal (21B). The second EMC component (3) includes a third positive input terminal (3A1) and a third negative input terminal (3B1). The first positive input terminal (21A) and the first negative input terminal (21B) are connected to the power supply plug-in (13), and the third positive input terminal (3A1) and the third negative input terminal (3B1) are connected to the DC charging plug-in (14).

4. A motor controller integrating high and low voltage charging functions according to claim 3, characterized in that, The first EMC component (2) further includes a support capacitor (22), and the second EMC component (3) further includes a magnetic ring. The first EMC component (2) is used for current filtering in motor drive mode, and the second EMC component (3) is used for current filtering in charging mode.

5. A motor controller integrating high and low voltage charging functions according to claim 3, characterized in that, It also includes a filter component (4), the input end of which is connected to the DC charging plug (14), and the output end of which is connected to the second EMC component (3).

6. A motor controller integrating high and low voltage charging functions according to claim 3, characterized in that, It also includes a housing (1), a first relay (Q1), a second relay (Q2), an IGBT assembly (12), and a four-phase output assembly (7) all located inside the housing (1). A heat-conducting platform (111) is provided inside the housing (1), and a first support column (112) is provided on one side of the heat-conducting platform (111). The first EMC assembly (2) is fixed on the first support column (112).

7. A motor controller integrating high and low voltage charging functions according to claim 3, characterized in that, It also includes a PDU plug-in (16) which is connected to the first EMC component (2).

8. A motor controller integrating high and low voltage charging functions according to claim 3, characterized in that, It also includes a first adapter component (5) and a second adapter component (6), wherein the first relay output terminal (Q12) of the first relay (Q1) is connected to the first EMC component (2) through the first adapter component (5), and the second relay output terminal (Q22) of the second relay (Q2) is connected to the second EMC component (3) through the second adapter component (6).

9. A motor controller integrating high and low voltage charging functions according to claim 1, characterized in that, The four-phase output component (7) is equipped with a three-phase current sensor (72).

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