Integrated motor controller heat dissipation structure and integrated motor controller

Abstract

This invention relates to an integrated motor controller heat dissipation structure, comprising an electronic control housing and an integrated control board, a vehicle-mounted bidirectional power supply board, and a drive power module installed within the electronic control housing. The electronic control housing has a power board cavity for mounting the vehicle-mounted bidirectional power supply board, and the power board cavity has a three-dimensional water channel for heat dissipation of the vehicle-mounted bidirectional power supply board. The three-dimensional water channel includes a water channel groove at the bottom of the electronic control housing and a sealing insert fixedly connected to the water channel groove. The water channel groove is arranged around the vehicle-mounted bidirectional power supply board and its two ends are respectively connected to an inlet and an outlet. The shape of the sealing insert is adapted to the water channel groove and forms a water flow channel between the water channel groove to accommodate the flow of cooling medium. This solves the problem of sand holes and water leakage that are easily generated due to the limitation of the die-casting process in the flow path of the transmission cooling water channel, and improves the integration of the motor controller.

Description

Technical Field

[0001] This invention relates to the field of motor controller technology, specifically to an integrated motor controller heat dissipation structure and an integrated motor controller. Background Technology

[0002] Electric vehicles consist of various high-voltage controllers, commonly including motor controllers, on-board chargers, DC-DC converters, battery management systems, and vehicle controllers. The motor controller is the core control device used to control the starting, running, forward / reverse, speed, and stopping of the vehicle's motor, as well as other electronic components. The on-board power supply charges the vehicle's battery and converts the vehicle's power into 220V AC power for external use. Deep integration of the various high-voltage controllers in an electric vehicle, achieving both simplicity and convergence, is a requirement for the performance and cost of the electric drive system in large-scale vehicle manufacturing. Integrated motor controllers incorporate various electronic components and PCB boards, thus requiring high-strength housings and excellent heat dissipation to prevent overheating and malfunction, thereby ensuring the safety of the electric vehicle and its occupants.

[0003] CN108882573A discloses a novel drive motor controller housing and a novel drive motor controller. The housing includes an internal mounting chamber for installing capacitor components, IGBT components, and busbar components. A cooling plate is located at the bottom of the housing, and the cooling plate contains cooling chambers corresponding to the upper and lower mounting chambers. The upper surface of the cooling plate has an opening communicating with the cooling chambers for installing IGBT components. The housing also has an inlet and an outlet communicating with the cooling chambers. The heat dissipation seal between the die-cast water channels in this invention requires the use of sealing rings and screws for installation, which is prone to risks such as sealing ring aging and screw loosening, resulting in low reliability and high component and manufacturing costs.

[0004] CN105578838A discloses a motor controller, including a controller housing, a capacitor module, and two inverter modules. A heat sink is installed inside the controller housing, with a cavity in the middle. The capacitor module is installed inside the cavity, and the two inverter modules are respectively installed on the top and bottom of the heat sink. Cooling water channels are provided on the heat sink, with inlets and outlets communicating with these channels. The cooling water channels dissipate heat from the capacitor module and the two inverter modules. However, the cooling water channels of this invention are formed by die casting. The flow path of the cooling water channels is limited by the die casting process, making them prone to pinholes and leaks. They cannot provide heat dissipation for specific electrical components, and the manufacturing process is quite difficult.

[0005] Undoubtedly, the technical solutions disclosed in the above two patent documents are a beneficial attempt in this field. Summary of the Invention

[0006] One objective of this invention is to provide an integrated motor controller heat dissipation structure. This structure integrates an on-board bidirectional power board within the motor controller and sets up a heat dissipation structure for the power board, which solves the problem of water leakage due to sand holes caused by the limitations of the die-casting process in the transmission cooling water channel flow path, and improves the integration of the motor controller. The second objective is to provide an integrated motor controller with the above-mentioned integrated motor controller heat dissipation structure.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows: An integrated motor controller heat dissipation structure includes an electronic control housing and an integrated control board, a vehicle-mounted bidirectional power board, and a drive power module installed within the electronic control housing. The electronic control housing has a power board cavity for mounting the vehicle-mounted bidirectional power board. The power board cavity has a three-dimensional water channel for heat dissipation of the vehicle-mounted bidirectional power board. The three-dimensional water channel includes a water channel groove at the bottom of the electronic control housing and a sealing insert fixedly connected to the water channel groove. The water channel groove is arranged around the vehicle-mounted bidirectional power board and its two ends are respectively connected to an inlet and an outlet. The shape of the sealing insert is adapted to the water channel groove and forms a water flow channel between the water channel groove to accommodate the flow of cooling medium.

[0008] Furthermore, the water channel has multiple streamlined heat dissipation protrusions distributed within it, which increase the heat dissipation area of ​​the electrical control housing. These streamlined heat dissipation protrusions also reduce water resistance.

[0009] Furthermore, the magnetic components of the vehicle-mounted bidirectional power supply board are located in the center of the board, and multiple power MOSFETs are distributed on both sides of the magnetic components. By designing the positions of the magnetic components and power MOSFETs on the vehicle-mounted bidirectional power supply board and coordinating them with the three-dimensional water channel for heat dissipation, the heat dissipation efficiency is improved.

[0010] Furthermore, the water channel is arranged around the magnetic components, forming mounting recesses for assembling the magnetic components. Assembling the magnetic components within these mounting recesses improves the space utilization of the electrical control housing and allows for heat dissipation of the magnetic components.

[0011] Furthermore, the cross-section of the water flow channel is L-shaped, wherein the horizontal surface of the water channel corresponding to the straight portion of the water flow channel contacts the power MOSFET, and the vertical surface of the water channel corresponding to the vertical portion of the water flow channel contacts the magnetic device. By adjusting the fit between the sealing insert and the water channel, the cross-section of the water flow channel can be set to L-shape to match the position of the magnetic device and power MOSFET on the vehicle bidirectional power supply board for targeted heat dissipation, thereby improving heat dissipation efficiency.

[0012] Furthermore, the space between the magnetic device and the vertical surface of the water channel is filled with a thermally conductive potting material. The thermally conductive potting material is made of silicone thermally conductive potting compound, which can reliably protect sensitive circuits and components over a wide range of temperature and humidity changes. It also has excellent electrical insulation properties, can withstand environmental pollution, and avoids damage to the product caused by environmental factors such as stress, vibration, and humidity.

[0013] Furthermore, the sealing insert is fixedly connected to the water channel via friction welding. The outer edge of the sealing insert is sealed by friction welding, which offers high and stable welding quality and is suitable for automated production lines, thereby improving the production efficiency of the electrical control housing.

[0014] Furthermore, the sealing insert is provided with multiple reinforcing ribs, which improves the strength and stability of the sealing insert structure.

[0015] An integrated motor controller includes the integrated motor controller heat dissipation structure described above. The integrated control board includes an auxiliary power supply circuit, an MCU microcontroller unit, multiple sampling circuits, and a CAN communication transceiver chip.

[0016] Furthermore, the MCU (Microcontroller Unit) is used to control the motor, power supply, and battery management system. By integrating multiple high-voltage controllers and sharing common circuit modules such as auxiliary power supply, control, and communication, the integration level of the motor controller is improved, and the cost is reduced.

[0017] The beneficial effects of this invention are: 1. Since the three-dimensional water channel is welded together with water channel grooves and sealing inserts, it replaces the water channel structure formed by die casting in the traditional electrical control housing. This makes the three-dimensional water channel shape more varied and can dissipate heat at the position of the heat-generating components of the bidirectional power board. It has high heat dissipation efficiency and reduces the problem of sand holes caused by uneven die casting force, which is more difficult to process in traditional die casting and can lead to water leakage in the housing.

[0018] 2. Because the motor housing integrates a three-dimensional water channel, the bidirectional power board does not require additional heat dissipation or a fixed housing and can be directly assembled. In the assembly of the integrated motor controller, the bidirectional power board and the drive power module integrated control board can be assembled directly onto the motor housing from the top. The assembly and after-sales disassembly process does not require flipping the housing, and there is no need to flip it in the middle. The assembly process is optimized and the assembly efficiency is high.

[0019] 3. Because the integrated control board integrates the functions of high-voltage controller for motor control, power control, and battery management, it saves on components such as connectors and shares a set of common circuit modules for control, communication, and auxiliary power, achieving deep integration and meeting the performance and cost requirements of large-scale vehicle manufacturing for electric drive systems. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the heat dissipation structure of an integrated motor controller; Figure 2 This is a bottom view of the electrical control housing; Figure 3 This is a cross-sectional schematic diagram of the heat dissipation structure of an integrated motor controller; Figure 4 This is a schematic diagram of the sealing insert. Figure 5 This is a schematic diagram of the cross-section of a three-dimensional waterway; Figure 6 This is a schematic diagram of the functional architecture of the integrated control board.

[0021] Technical features and markings in the diagram: 1. Electrical control housing; 11. Heat dissipation protrusion; 12. Assembly groove; 13. Water outlet; 14. Water inlet; 15. Water channel. Sealing insert 2, water flow channel 21, reinforcing rib 22 Vehicle-mounted bidirectional power supply board 3, magnetic components 31, power MOSFETs 32. Integrated control board 4 Drive power module 5. Detailed Implementation

[0022] The embodiments of the present invention will be described below with reference to the accompanying drawings and preferred embodiments. Those skilled in the art can understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be understood that the preferred embodiments are only for illustrating the present invention and are not intended to limit the scope of protection of the present invention.

[0023] It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. Therefore, the illustrations only show the components related to the present invention and are not drawn according to the actual number, shape and size of the components in the actual implementation. In the actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0024] like Figure 1As shown, this embodiment provides an integrated motor controller heat dissipation structure, including an electronic control housing 1 and an integrated control board 4, a vehicle-mounted bidirectional power board 3, and a drive power module 5 installed within the electronic control housing 1. The electronic control housing 1 has a power board cavity for mounting the vehicle-mounted bidirectional power board 3. The power board cavity contains a three-dimensional water channel for heat dissipation of the vehicle-mounted bidirectional power board 3. The three-dimensional water channel includes a water channel groove 15 located at the bottom of the electronic control housing 1 and a sealing insert 2 fixedly connected to the water channel groove 15. The water channel groove 15 surrounds the vehicle-mounted bidirectional power board 3 and its two ends are respectively connected to an inlet 14 and an outlet 13. The shape of the sealing insert 2 is adapted to the water channel groove 15, forming a water flow channel 21 between the water channel groove 15 to accommodate the flow of cooling medium. In this embodiment, the cooling medium is water.

[0025] Since the three-dimensional water channel is welded together with the water channel 15 and the sealing insert 2, it replaces the water channel structure formed by die casting in the traditional electrical control housing 1, making the three-dimensional water channel shape more varied. It can dissipate heat at the position of the heat-generating component of the bidirectional power board, with high heat dissipation efficiency. It also reduces the problem of water leakage caused by sand holes due to uneven die casting force, which is difficult to process in traditional die casting.

[0026] like Figure 2 and Figure 5 As shown, in this embodiment, the water channel 15 has multiple streamlined heat dissipation protrusions 11 distributed within it. These protrusions 11 are used to increase the heat dissipation area of ​​the electronic control housing 1. The streamlined heat dissipation protrusions 11 also reduce water resistance.

[0027] like Figure 4 and Figure 5 As shown, in this embodiment, the magnetic device 31 of the vehicle-mounted bidirectional power supply board 3 is located in the middle of the vehicle-mounted bidirectional power supply board 3, and multiple power MOSFETs 32 are distributed on both sides of the magnetic device 31. The magnetic device 31 on the vehicle-mounted bidirectional power supply board 3 mainly consists of electronic transformers and inductors. By designing the positions of the magnetic device 31 and power MOSFETs 32 on the vehicle-mounted bidirectional power supply board 3 and coordinating them with the three-dimensional water channel for heat dissipation, the heat dissipation efficiency is improved.

[0028] like Figure 4 and Figure 5 As shown, in this embodiment, the water channel 15 is arranged around the magnetic device 31 and forms an assembly groove 12 for assembling the magnetic device 31. Assembling the magnetic device 31 in the assembly groove 12 improves the space utilization of the electronic control housing 1 and allows for heat dissipation of the magnetic device 31.

[0029] like Figure 4 and Figure 5As shown, in this embodiment, the cross-section of the water flow channel 21 is L-shaped. The horizontal surface of the water channel 15 corresponding to the straight portion of the water flow channel 21 contacts the power MOSFET 32, and the vertical surface of the water channel 15 corresponding to the vertical portion of the water flow channel 21 contacts the magnetic device 31. By adjusting the fit between the sealing insert 2 and the water channel 15, the cross-section of the water flow channel 21 can be set to an L-shape to match the positions of the magnetic device 31 and the power MOSFET 32 on the vehicle-mounted bidirectional power board 3 for targeted heat dissipation, thus improving heat dissipation efficiency.

[0030] In this embodiment, the space between the magnetic device 31 and the vertical surface of the water channel 15 is filled with a thermally conductive potting material. The thermally conductive potting material is silicone thermally conductive potting compound, which can reliably protect sensitive circuits and components over a wide range of temperature and humidity changes. It also has excellent electrical insulation properties, can withstand environmental pollution, and avoids damage to the product caused by environmental factors such as stress, vibration, and humidity.

[0031] like Figure 3 As shown, in this embodiment, the sealing insert 2 is provided with multiple reinforcing ribs 22, which improves the strength and stability of the sealing insert 2 structure. The sealing insert 2 is fixedly connected to the water channel 15 by friction welding. The outer edge of the sealing insert 2 is sealed by friction welding. Friction welding has good welding quality and stability, and is suitable for automated production lines, which can improve the production efficiency of the electrical control housing 1.

[0032] This embodiment also provides a motor controller, including the integrated motor controller heat dissipation structure described above. The integrated control board 4 includes an auxiliary power supply circuit, an MCU microcontroller unit, multiple sampling circuits, and a CAN communication transceiver chip. The auxiliary power supply circuit supplies power to the internal low-voltage chips and circuits. The sampling circuits include a CC sampling circuit, a CP sampling circuit, a pedal sampling circuit, a total voltage sampling circuit, and a total current sampling circuit. The CAN communication transceiver chip can communicate with the vehicle's main unit.

[0033] Because the motor housing integrates a three-dimensional water channel, the bidirectional power board does not require additional heat dissipation or a fixed housing and can be directly assembled. In the assembly of the integrated motor controller, the bidirectional power board, drive power module 5 and integrated control board 4 can be assembled directly onto the motor housing from the top. The assembly and after-sales disassembly process does not require flipping the housing, and there is no need to flip it in the middle. The assembly process is optimized and the assembly efficiency is high.

[0034] like Figure 6As shown in this embodiment, the MCU microcontroller unit is used to control the motor, power supply, and battery management system. By integrating multiple high-voltage controllers through the MCU microcontroller unit, not only are connectors and other components saved, but auxiliary power, control, communication, and other common circuit modules are also shared. This improves the integration of the motor controller, reduces costs, and meets the performance and cost requirements of large-scale vehicle manufacturing for electric drive systems.

[0035] The above embodiments are merely preferred embodiments provided to fully illustrate the present invention, and the scope of protection of the present invention is not limited thereto. Equivalent substitutions or modifications made by those skilled in the art based on the present invention are all within the scope of protection of the present invention.

Claims

1. An integrated motor controller heat sink structure, comprising: The device includes an electronic control housing (1) and an integrated control board (4), a vehicle bidirectional power board (3), and a drive power module (5) installed in the electronic control housing (1). The electronic control housing (1) is provided with a power board cavity for installing the vehicle bidirectional power board (3). The power board cavity is provided with a three-dimensional water channel for heat dissipation of the vehicle bidirectional power board (3). The three-dimensional water channel includes a water channel groove (15) at the bottom of the electronic control housing (1) and a sealing insert (2) fixedly connected to the water channel groove (15). The water channel groove (15) is arranged around the vehicle bidirectional power board (3) and its two ends are respectively connected to the water inlet (14) and the water outlet (13). The shape of the sealing insert (2) is adapted to the water channel groove (15) and forms a water flow channel (21) between the water channel groove (15) to accommodate the flow of cooling medium. The magnetic device (31) of the vehicle bidirectional power board (3) is located in the middle of the vehicle bidirectional power board (3), and multiple power MOS transistors (32) are distributed on both sides of the magnetic device (31); the water channel (15) is arranged around the magnetic device (31) and forms an assembly groove (12) for assembling the magnetic device (31); the water flow channel (21) includes a straight part and a vertical part, wherein the horizontal surface of the water channel (15) corresponding to the straight part of the water flow channel (21) contacts the power MOS transistor (32), and the vertical surface of the water channel (15) corresponding to the vertical part of the water flow channel (21) contacts the magnetic device (31).

2. The integrated motor controller heat sink structure of claim 1, wherein, The water channel (15) has multiple streamlined heat dissipation protrusions (11) distributed inside, which are used to increase the heat dissipation area of ​​the electronic control housing (1).

3. The integrated motor controller heat sink structure of claim 1, wherein, The cross-section of the water flow channel (21) is L-shaped.

4. The integrated motor controller heat sink structure of claim 1, wherein, The space between the magnetic device (31) and the vertical surface of the water channel (15) is filled with thermally conductive potting material.

5. The integrated motor controller heat dissipation structure according to claim 1, characterized in that, The sealing insert (2) is fixedly connected to the water channel (15) by friction welding.

6. The integrated motor controller heat sink structure of claim 5, wherein, The sealing insert (2) is provided with multiple reinforcing ribs (22).

7. An integrated motor controller, characterized by The integrated motor controller heat dissipation structure includes any one of claims 1-6, wherein the integrated control board (4) includes an auxiliary power supply circuit, an MCU microcontroller unit, multiple sampling circuits and a CAN communication transceiver chip.

8. The integrated motor controller of claim 7, wherein, The MCU microcontroller unit is used to perform motor control, power supply control, and battery management system control.

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