An air-cooled vehicle-mounted drive motor controller

Abstract

The present invention relates to the field of vehicle control technology, and specifically to an air-cooled vehicle-mounted drive motor controller, including a radiator and a control unit installed thereon, the control unit including a drive board and a plurality of conductive columns and a plurality of IGBT single tubes installed on the drive board, characterized in that: it also includes a film capacitor, a temperature sensor, a current sensor and an MCU, the radiator is provided with an upper bridge arm and a lower bridge arm, the installation position between the two is correspondingly provided with a film capacitor and a conductive column, the IGBT single tube is symmetrically provided with two columns corresponding to the upper bridge arm and the lower bridge arm respectively, the temperature sensor and the current sensor are both connected to the MCU, the MCU runs a temperature control program, the temperature control program predicts the predicted temperature Tt of the radiator after t time according to the current temperature T and the drive current I, and generates the upper limit value of the drive current allowed according to the predicted temperature Tt. The beneficial technical effects of the present invention include: improving the heat dissipation efficiency and ensuring the normal operation of the vehicle.

Description

Technical Field

[0001] The present invention relates to the technical field of vehicle control, and in particular to an air-cooled vehicle-mounted drive motor controller. Background Art

[0002] With the lightweight and cost pressure of automobiles, it is a consensus standard to make the drive motor controller small in size, high in power density and low in cost while ensuring performance. The motor controller is equipped with power components, which will generate a lot of heat during operation. If the heat cannot be effectively dissipated, it will affect the service life of the product itself and even pose a safety hazard. During the driving process of the car, in order to avoid overheating of the on-board drive motor controller, the real-time temperature of the controller needs to be controlled. At the same time, the requirements for maximizing vehicle performance should be taken into account. However, there is currently a lack of technical solutions for temperature control of on-board drive motor controllers.

[0003] Chinese patent CN103204072A, published on July 17, 2013, discloses a vehicle-mounted controller, including: a rectifier power module, an inverter power module and a control circuit, wherein the rectifier power module, the inverter power module and the power battery are connected in parallel, the rectifier power module, the inverter power module and the power battery are connected via a busbar, the rectifier power module is connected to the generator, the inverter power module is connected to the drive motor, and the control circuit is separately connected to the rectifier power module and the inverter power module. Its technical solution designs the generator controller and the drive motor controller as a rectifier power module and an inverter power module, organically integrates and connects these two modules into one, and controls them through a common control circuit. After optimized integration, the present invention can be directly installed on the vehicle as a component. However, its technical solution cannot control the temperature of the vehicle-mounted drive motor controller and cannot effectively guarantee it. Summary of the invention

[0004] The technical problem to be solved by the present invention is that there is currently a lack of a vehicle-mounted drive motor controller with efficient heat dissipation and temperature control function. An air-cooled vehicle-mounted drive motor controller is proposed, which can improve the heat dissipation efficiency and more effectively control the temperature.

[0005] In order to solve the above technical problems, the present invention adopts the following technical solutions: an air-cooled vehicle-mounted drive motor controller, comprising a radiator and a control unit installed thereon, the control unit comprising a drive board and a plurality of conductive columns and a plurality of IGBT single tubes installed on the drive board, and also comprising a thin film capacitor, a temperature sensor, a current sensor and an MCU, the radiator is provided with an upper bridge arm and a lower bridge arm, and a thin film capacitor and a conductive column are correspondingly arranged at the installation position between the two, the IGBT single tube is symmetrically provided with two columns corresponding to the upper bridge arm and the lower bridge arm respectively, the IGBT single tube is connected to the vehicle-mounted motor drive end through the conductive column, the temperature sensor detects the current temperature T of the radiator, the current sensor detects the drive current I of the vehicle-mounted motor, the temperature sensor and the current sensor are both connected to the MCU, the MCU runs a temperature control program, the temperature control program predicts the predicted temperature Tt of the radiator after t time according to the current temperature T and the drive current I, and generates an allowable upper limit value of the drive current according to the predicted temperature Tt.

[0006] Preferably, when the MCU calculates the predicted temperature Tt, the following steps are performed:

[0007] The MCU periodically reads the current temperature T of the radiator and the driving current I of the vehicle-mounted motor;

[0008] The MCU calculates Tt=T*(1+k1*I-k2*T), where k1 and k2 are preset constant coefficients;

[0009] The calculated Tt is the predicted temperature Tt of the radiator after time t.

[0010] Preferably, when the MCU calculates the predicted temperature Tt, the following steps are further performed:

[0011] The MCU controls the driving current I to increase instantaneously to a preset driving current Im, and after a preset time △t, returns to the driving current I;

[0012] The current temperature values ​​of the radiator before and after the driving current increases are detected respectively, which are recorded as T1 and T2;

[0013] When the driving current I is in an increasing trend, the MCU calculates k3=(T2-T1) / T0, where T0 is a preset constant value, and then calculates Tt=T*(1+k1*k3*I-k2*k3*T);

[0014] When the driving current I is in a decreasing trend, the MCU calculates k3=T0 / (T2-T1), and then calculates Tt=T*(1+k1*k3*I-k2*k3*T).

[0015] Preferably, the method for obtaining the preset driving current Im includes:

[0016] Under laboratory conditions, the driving current I is gradually increased from a preset value according to a preset step size, while detecting the acceleration generated by the vehicle;

[0017] The vehicle acceleration is kept below a preset threshold, and the maximum value of the driving current I is taken as the preset driving current Im.

[0018] Preferably, the method for obtaining the preset time length Δt includes:

[0019] Under laboratory conditions, the driving current is set to Im and the speed change value generated by the vehicle is detected;

[0020] When the speed change value reaches the preset threshold, the duration of the duration is used as the preset duration Δt.

[0021] Preferably, it also includes a pressure strip and a ceramic heat conducting sheet, each IGBT single tube is pressed onto the heat sink through a corresponding pressure strip, and a ceramic heat conducting sheet is provided between the heat sink and the IGBT single tube;

[0022] It also includes a film capacitor heat sink, and the contact surface between the film capacitor heat sink and the radiator is provided with thermal conductive silicone grease.

[0023] Preferably, the driving board is a six-layer circuit board, and the conductive columns include a positive conductive column, a negative conductive column, a U-phase conductive column, a V-phase conductive column, and a W-phase conductive column, which are respectively fixedly connected to the driving board.

[0024] Preferably, it also includes a heat-conducting block and an insulating heat-conducting pad. A heat-conducting block is arranged at the heat sink position below the installation position of the positive conductive column and the negative conductive column, and an insulating heat-conducting pad is arranged above the heat-conducting block.

[0025] Preferably, it also includes a thermally conductive fixing glue, and the upper and lower positions of the IGBT single tube pin are covered with the thermally conductive fixing glue.

[0026] Preferably, a graphite sheet is attached to the surface of the IGBT single tube.

[0027] Preferably, the busbar input and three-phase output terminals of the control unit adopt simple quick-insert installation connectors.

[0028] Preferably, the radiator is a 6063 aluminum profile radiator.

[0029] Preferably, the heat-conducting block is a heat-conducting aluminum block.

[0030] The beneficial technical effects of the present invention include: improving the heat dissipation efficiency of thin-film capacitors, conductive columns and IGBT single tubes through the upper bridge arm and the lower bridge arm; achieving temperature control through a temperature control program, which can effectively avoid overheating of the vehicle-mounted drive motor controller and ensure the normal operation of the vehicle; forcing the vehicle-mounted drive motor controller to generate heat by increasing the drive current in a short time, and detecting the temperature change value after a preset time, which can reflect the real-time heat dissipation efficiency of the vehicle-mounted drive motor controller and more effectively predict the temperature of the radiator, thereby calculating the maximum allowable value of the current drive current, and further ensuring the safety of the vehicle-mounted drive motor controller; by redesigning the overall structure of the drive motor controller, the volume of the drive motor controller is reduced, the power density is increased and the cost is reduced.

[0031] Other features and advantages of the present invention will be disclosed in detail in the following specific embodiments and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The present invention will be further described below in conjunction with the accompanying drawings:

[0033] Figure 1 The figure is a schematic diagram of the structure of a vehicle-mounted drive motor controller according to an embodiment of the present invention.

[0034] Figure 2 Schematic diagram of the flow of a method for calculating predicted temperature Tt according to an embodiment of the present invention.

[0035] Figure 3 Schematic diagram of a method for more accurately calculating and predicting temperature Tt according to an embodiment of the present invention.

[0036] Figure 4 It is a side view of a vehicle-mounted drive motor controller according to an embodiment of the present invention.

[0037] Figure 5 This is an exploded view of a vehicle-mounted drive motor controller according to an embodiment of the present invention.

[0038] Figure 6 It is a partial view of the top of the heat sink according to an embodiment of the present invention.

[0039] Figure 7 It is a partial view of the side of the heat sink according to the embodiment of the present invention.

[0040] Figure 8 Schematic diagram of the structure of a thin film capacitor according to an embodiment of the present invention.

[0041] Among them, 1. Upper cover, 2. Terminal seat, 3. Upper shell, 4. Simple quick-plug installation connector, 5. Control board, 6. Conductive column, 7. Driver board, 8. IGBT single tube, 9. Radiator, 91. Upper bridge arm, 92. Lower bridge arm, 10. Ceramic thermal conductive sheet, 11. Film capacitor, 12. Thermal block, 13. Pressure strip, 14. Insulated thermal pad, 15. Film capacitor heat sink, 16. Thermal fixing glue, 17. Graphite sheet, 18. Thermal grease. DETAILED DESCRIPTION

[0042] The technical solutions of the embodiments of the present invention are explained and described below in conjunction with the drawings of the embodiments of the present invention, but the following embodiments are only preferred embodiments of the present invention, not all. Based on the embodiments in the implementation mode, other embodiments obtained by those skilled in the art without creative work are all within the protection scope of the present invention.

[0043] In the following description, terms such as "inside", "outside", "up", "down", "left", "right", etc. that indicate directions or positional relationships are only used to facilitate the description of the embodiments and simplify the description, and do not indicate or imply that the referred device or element must have a specific direction, be constructed and operate in a specific direction. Therefore, it should not be understood as a limitation of the present invention.

[0044] An air-cooled vehicle drive motor controller, see the attached Figure 1 , including a radiator 9 and a control unit installed thereon, the control unit includes a driving board 7 and a plurality of conductive columns 6 and a plurality of IGBT single tubes 8 installed on the driving board 7, and also includes a thin film capacitor 11, a temperature sensor, a current sensor and an MCU, the radiator 9 is provided with an upper bridge arm 91 and a lower bridge arm 92, and the installation position between the two is correspondingly provided with a thin film capacitor 11 and a conductive column 6, the IGBT single tube 8 is symmetrically provided with two columns corresponding to the upper bridge arm 91 and the lower bridge arm 92, respectively, the IGBT single tube 8 is connected to the vehicle motor driving end through the conductive column 6, the temperature sensor detects the current temperature T of the radiator 9, the current sensor detects the driving current I of the vehicle motor, the temperature sensor and the current sensor are both connected to the MCU, the MCU runs a temperature control program, the temperature control program predicts the predicted temperature Tt of the radiator 9 after t time according to the current temperature T and the driving current I, and generates an upper limit value of the driving current allowed according to the predicted temperature Tt.

[0045] Please see attached Figure 2 , when the MCU calculates the predicted temperature Tt, it performs the following steps:

[0046] Step A01) MCU periodically reads the current temperature T of the radiator 9 and the driving current I of the vehicle motor;

[0047] Step A02) MCU calculates Tt=T*(1+k1*I-k2*T), where k1 and k2 are preset constant coefficients;

[0048] The Tt calculated in step A03) is the predicted temperature Tt of the radiator 9 after a period of time t.

[0049] The predicted temperature Tt is related to the current temperature T and the current driving current I, that is, Tt=T+a1(I-I0), where a1 is the coefficient and I0 is the reference current. The reference current is not a constant, and its appropriate reference current value is not the same for different current temperatures T. That is, I0=a2*T, a2 is the coefficient. Therefore, the calculation formula Tt=T*(1+k1*I-k2*T) is obtained, which is used to calculate the predicted temperature Tt. The upper bridge arm 91 and the lower bridge arm 92 are used to improve the heat dissipation efficiency of the thin film capacitor 11, the conductive column 6 and the IGBT single tube 8; the temperature control program is used to control the temperature, which can effectively avoid overheating of the vehicle-mounted drive motor controller and ensure the normal operation of the vehicle.

[0050] On the other hand, this embodiment also provides a more accurate solution for calculating the predicted temperature Tt. Figure 3 When the MCU calculates the predicted temperature Tt, it also performs the following steps:

[0051] Step B01) MCU controls the driving current I to increase instantaneously to a preset driving current Im, and after a preset time △t, restores to the driving current I;

[0052] Step B02) respectively detecting the current temperature values ​​of the radiator 9 before and after the driving current increases, which are recorded as T1 and T2;

[0053] Step B03) When the driving current I is in an increasing trend, the MCU calculates k3=(T2-T1) / T0, where T0 is a preset constant value, and then calculates Tt=T*(1+k1*k3*I-k2*k3*T);

[0054] Step B04) When the driving current I is in a decreasing trend, the MCU calculates k3=T0 / (T2-T1), and then calculates Tt=T*(1+k1*k3*I-k2*k3*T).

[0055] The temperature value of the radiator 9 is not only related to the current temperature T and the drive current I, but also to the heat dissipation conditions at that time. The real-time heat dissipation conditions of the vehicle are changing and difficult to predict accurately. Therefore, this embodiment actively increases the drive current I to observe the temperature changes of the radiator 9 under real-time conditions. A real-time heat dissipation condition test is thus performed, and the characterization of the real-time heat dissipation condition is obtained from the test results, that is, k3 is used to characterize it. When the drive current I is in an increasing trend, the temperature T will rise, and at this time k3 = (T2-T1) / T0, and when the drive current I is in a decreasing trend, the temperature T will drop, and at this time k3 = T0 / (T2-T1). By increasing the drive current for a short time, forcing the vehicle-mounted drive motor controller to heat up, and detecting the temperature change value after a preset period of time, it can reflect the real-time heat dissipation efficiency of the vehicle-mounted drive motor controller, and more effectively predict the temperature of the radiator 9, thereby calculating the maximum allowable value of the current drive current, and further ensuring the safety of the vehicle-mounted drive motor controller.

[0056] The method for obtaining the preset driving current Im includes: under laboratory conditions, gradually increasing the driving current I from a preset value according to a preset step length, while detecting the acceleration generated by the vehicle;

[0057] The vehicle acceleration is kept below a preset threshold, and the maximum value of the driving current I is taken as the preset driving current Im.

[0058] The method for obtaining the preset time length △t includes: under laboratory conditions, setting the driving current to Im and detecting the speed change value generated by the vehicle;

[0059] When the speed change value reaches the preset threshold, the duration of the change is used as the preset duration △t.

[0060] This embodiment also includes a pressure strip 13 and a ceramic heat conducting sheet 10. Each IGBT single tube 8 is pressed onto the heat sink 9 through the corresponding pressure strip 13. A ceramic heat conducting sheet 10 is provided between the heat sink 9 and the IGBT single tube 8. This structure can reduce thermal resistance, has a large heat dissipation area, and has a good heat dissipation effect.

[0061] This embodiment also includes a film capacitor heat sink 15, and the contact surface of the film capacitor heat sink 15 and the radiator 9 is provided with thermal conductive silicone grease 18. More specifically, the film capacitor 11 is fixed in the middle of the radiator 9, an aluminum plate is embedded at the bottom of the film capacitor 11, and the back of the aluminum plate is coated with thermal conductive silicone grease 18, that is, the film capacitor heat sink 15, and the heat of the film capacitor 11 is transferred to the radiator 9 through the plate.

[0062] The pins of the IGBT single tube 8 of this embodiment are welded and fixed to the driving board 7. The driving board 7 is a six-layer circuit board. The conductive column 6 includes a positive conductive column, a negative conductive column, a U-phase conductive column, a V-phase conductive column, and a W-phase conductive column, which are respectively fixed and connected to the driving board 7 by bolts. This layout method has a good current balancing effect.

[0063] The present embodiment also includes a heat-conducting block 12 and an insulating heat-conducting pad 14. A heat-conducting block 12 (aluminum block) is arranged at the position of the radiator 9 below the installation position of the positive conductive column and the negative conductive column, and an insulating heat-conducting pad 14 is arranged above the heat-conducting block 12. The heat of the driving board 7 can be transferred to the radiator 9 through the heat-conducting block 12, thereby improving the overall heat dissipation effect.

[0064] This embodiment also includes a heat-conducting fixing glue 16, and the upper and lower positions of the pins of the IGBT single tube 8 are covered with the heat-conducting fixing glue 16, which can conduct heat to the radiator 9. A graphite sheet 17 is attached to the surface of the plastic shell of the IGBT single tube 8, and the graphite sheet 17 extends to both sides of the radiator 9, so that the IGBT single tube 8 can achieve a double-sided heat dissipation effect and improve the overall performance.

[0065] By redesigning the overall structure of the drive motor controller, the volume of the drive motor controller is reduced, the power density is increased and the cost is reduced.

[0066] It should be noted that the control unit part of this product also includes components such as an upper cover plate 1, a terminal seat 2, an upper shell 3, a control board 5 (shown in the attached drawings), which are all existing technologies and will not be described in detail.

[0067] The busbar input and three-phase output terminals of the control unit of this embodiment adopt a simple quick-insert installation connector 4, which is easy to install and low in cost.

[0068] The above is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Those skilled in the art should understand that the present invention includes but is not limited to the contents described in the drawings and the above specific embodiments. Any modification that does not deviate from the functional and structural principles of the present invention will be included in the scope of the claims.

Claims

1. An air-cooled vehicle-mounted drive motor controller, comprising a radiator and a control unit mounted thereon, wherein the control unit comprises a drive board and a plurality of conductive columns and a plurality of IGBT single tubes mounted on the drive board, characterized in that: It also includes a thin film capacitor, a temperature sensor, a current sensor and an MCU. The radiator is provided with an upper bridge arm and a lower bridge arm, and a thin film capacitor and a conductive column are correspondingly provided at the installation position between the two. The IGBT single tube is symmetrically provided with two columns corresponding to the upper bridge arm and the lower bridge arm respectively. The IGBT single tube is connected to the vehicle motor drive end through the conductive column. The temperature sensor detects the current temperature T of the radiator, and the current sensor detects the drive current I of the vehicle motor. The temperature sensor and the current sensor are both connected to the MCU. The MCU runs a temperature control program. The temperature control program predicts the predicted temperature Tt of the radiator after t time according to the current temperature T and the drive current I, and generates an allowable upper limit value of the drive current according to the predicted temperature Tt. When the MCU calculates the predicted temperature Tt, the following steps are performed: The MCU periodically reads the current temperature T of the radiator and the driving current I of the vehicle-mounted motor; The MCU calculates Tt=T*(1+k1*I-k2*T), where k1 and k2 are preset constant coefficients; The calculated Tt is the predicted temperature Tt of the radiator after time t.

2. The air-cooled vehicle-mounted drive motor controller according to claim 1, characterized in that: When the MCU calculates the predicted temperature Tt, the following steps are also performed: The MCU controls the driving current I to increase instantaneously to a preset driving current Im, and after a preset time △t, returns to the driving current I; The current temperature values ​​of the radiator before and after the driving current increases are detected respectively, which are recorded as T1 and T2; When the driving current I is in an increasing trend, the MCU calculates k3=(T2-T1) / T0, where T0 is a preset constant value, and then calculates Tt=T*(1+k1*k3*I-k2*k3*T); When the driving current I is in a decreasing trend, the MCU calculates k3=T0 / (T2-T1), and then calculates Tt=T*(1+k1*k3*I-k2*k3*T).

3. An air-cooled vehicle-mounted drive motor controller according to claim 1 or 2, characterized in that: The method for obtaining the preset driving current Im includes: Under laboratory conditions, the driving current I is gradually increased from a preset value according to a preset step size, while detecting the acceleration generated by the vehicle; The vehicle acceleration is kept below a preset threshold, and the maximum value of the driving current I is taken as the preset driving current Im.

4. The air-cooled vehicle-mounted drive motor controller according to claim 1 or 2, characterized in that: The method of obtaining the preset time length △t includes: Under laboratory conditions, the driving current is set to Im and the speed change value generated by the vehicle is detected; When the speed change value reaches the preset threshold, the duration of the duration is used as the preset duration Δt.

5. The air-cooled vehicle-mounted drive motor controller according to claim 1 or 2, characterized in that: It also includes a pressure strip and a ceramic heat conducting sheet. Each IGBT single tube is pressed onto the heat sink through a corresponding pressure strip. A ceramic heat conducting sheet is provided between the heat sink and the IGBT single tube. It also includes a film capacitor heat sink, and the contact surface between the film capacitor heat sink and the radiator is provided with thermal conductive silicone grease.

6. An air-cooled vehicle-mounted drive motor controller according to claim 1 or 2, characterized in that: The driving board is a six-layer circuit board, and the conductive columns include a positive conductive column, a negative conductive column, a U-phase conductive column, a V-phase conductive column, and a W-phase conductive column, which are respectively fixedly connected to the driving board.

7. The air-cooled vehicle-mounted drive motor controller according to claim 1 or 2, characterized in that: It also includes a heat-conducting block and an insulating heat-conducting pad. The heat-conducting block is arranged at the radiator position below the installation position of the positive conductive column and the negative conductive column, and the insulating heat-conducting pad is arranged above the heat-conducting block.

8. An air-cooled vehicle-mounted drive motor controller according to claim 1 or 2, characterized in that: It also includes heat-conducting fixing glue, and the upper and lower positions of the IGBT single tube pin are covered with heat-conducting fixing glue.

9. An air-cooled vehicle-mounted drive motor controller according to claim 1 or 2, characterized in that: A graphite sheet is attached to the surface of the IGBT single tube.

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