Low cost compact motor controller assembly structure for hybrid vehicles

Abstract

The application discloses a low-cost compact motor controller assembly structure for a hybrid automobile, and relates to the technical field of automobile hybrid power systems.The low-cost compact motor controller assembly structure comprises a motor controller body and a transmission body.The motor controller body comprises a shell assembly and a three-phase copper bar.A high-voltage connector mounting channel penetrating in the up-down direction is arranged in the interior of the shell assembly, and the three-phase copper bar extends into the high-voltage connector mounting channel.A three-phase high-voltage connector is arranged on the transmission body at a position corresponding to the high-voltage connector mounting channel.The motor controller body is connected with the transmission body, the three-phase high-voltage connector extends into the high-voltage connector mounting channel and is connected with the three-phase copper bar.The low-cost compact motor controller assembly structure can reduce cost, improve space utilization, and make the layout more compact.

Description

Technical Field

[0001] This invention relates to automotive hybrid power systems, and more specifically to a low-cost, compact motor controller assembly structure for hybrid vehicles. Background Technology

[0002] Driven by both energy and environmental pressures, the automotive industry is accelerating its transition from traditional gasoline-powered vehicles to new energy vehicles. Currently, due to limitations in key component technologies such as batteries, the development of electric vehicles is constrained, making hybrid electric vehicles (HEVs) indispensable in the new energy vehicle market. HEVs, which use both an electric motor and an internal combustion engine to power the vehicle, present significant challenges to cost control due to the increased overall cost resulting from the addition of an electric drive system. Furthermore, the limited engine compartment space not only accommodates internal combustion engine components but also requires the installation of a motor controller assembly, further complicating the overall engine compartment layout. Therefore, low-cost, high-energy-density motor controllers are one of the primary development goals of existing motor controller designs. The main installation and layout schemes for motor controllers in automotive engine compartments are: First, the motor controller is integrated with the transmission and supplied to the vehicle as a multi-in-one hybrid powertrain. This method has a compact structure but poor maintainability and adaptability to multiple vehicle models. Second, the motor controller assembly is installed on the vehicle through an adapter bracket, and the current is conducted between the motor and the controller through an external three-phase wiring harness. This method is flexible in layout, but it adds an extra high-voltage wiring harness and connecting bracket, which is not conducive to cost, weight and compactness of the structural layout.

[0003] CN108032906A discloses a motor controller mounting bracket assembly, including a first and second crossbeam arranged in parallel, and a longitudinal beam arranged vertically between the two crossbeams. Connectors for connecting to a vehicle frame are fixed to both ends of the first and second crossbeams. Mounting components for fixing the motor controller are provided on the first, second, and longitudinal beams. This motor controller mounting bracket assembly not only has a simple structure and high overall support strength, facilitating assembly with the motor controller and related components, but also boasts high precision, facilitating connection to the vehicle frame, and providing high connection strength, thus reducing costs. Undoubtedly, the technical solution disclosed in the above patent document is a beneficial attempt in its respective technical field. However, this method adds an extra beam structure, leaving room for further improvement in cost reduction and weight reduction.

[0004] CN110943581A discloses an integrated electric drive structure comprising a motor controller, a DC-DC converter, a gearbox, and a motor. The structure includes a motor, a motor controller, a gearbox, and a DC-DC converter. The motor includes a motor housing and a motor shaft with one end connected to the motor housing. The gearbox includes a gearbox housing and a bearing seat disposed within the gearbox housing. The other end of the motor shaft is inserted into the bearing seat. The motor housing and the gearbox housing are fixed together. The motor controller and the DC-DC converter are fixed above the motor housing and the gearbox housing. The motor controller and the motor are electrically connected via a rigid connection structure. This invention integrates the motor, motor controller, DC-DC converter, and gearbox into a single drive system, requiring only one mounting bracket to be fixed to the vehicle, eliminating the need for separate installation of the controller and motor, thus saving space. Undoubtedly, the technical solution disclosed in the above patent document represents a beneficial attempt in the relevant technical field; however, this approach suffers from poor maintainability and adaptability to various vehicle models. Summary of the Invention

[0005] In view of this, the purpose of the present invention is to provide a low-cost, compact motor controller assembly structure for hybrid vehicles, which can reduce costs, improve space utilization, and make the layout more compact.

[0006] The present invention discloses a low-cost, compact motor controller assembly structure for hybrid vehicles, comprising a motor controller body and a transmission body; the motor controller body includes a housing assembly and a three-phase copper busbar, the housing assembly having a high-voltage connector mounting channel extending vertically inside, and the three-phase copper busbar extending into the high-voltage connector mounting channel; the transmission body has a three-phase high-voltage connector positioned corresponding to the high-voltage connector mounting channel. The motor controller body is connected to the transmission body, and the three-phase high-voltage connector extends into the high-voltage connector mounting channel and is connected to the three-phase copper busbar.

[0007] Furthermore, the three-phase high-voltage connector includes a base and a connector head. The bottom of the base is connected to the transmission body, and the connector head protrudes upward from the middle of the base.

[0008] Furthermore, the three-phase high-voltage connector also includes a sealing ring surrounding the outside of the connector head. A sealing end face is provided on the lower side of the housing assembly corresponding to the periphery of the high-voltage connector mounting channel. The upper surface of the sealing ring is in close contact with the sealing end face, and the lower surface of the sealing ring is in close contact with the base.

[0009] Furthermore, the three-phase high-voltage connector also includes a three-phase high-voltage connector shielding layer surrounding the outside of the sealing ring, the upper surface of the three-phase high-voltage connector shielding layer being in close contact with the sealing end face, and the lower surface of the three-phase high-voltage connector shielding layer being in close contact with the base.

[0010] Furthermore, the three-phase copper busbar is provided with bolt through holes, and the three-phase high-voltage connector is provided with threaded holes. By passing a connecting bolt through the bolt through holes and connecting it to the threaded holes, the three-phase copper busbar is connected to the three-phase high-voltage connector.

[0011] Furthermore, the housing assembly includes a main housing and a housing cover disposed on the upper side of the main housing. The high-voltage connector mounting channel extends through both the housing cover and the main housing in the vertical direction. The housing cover is provided with a process cover plate for sealing the high-voltage connector mounting channel.

[0012] Furthermore, it also includes an air filter mounting bracket, and an air filter bracket mounting boss is provided on the outside of the main housing. The air filter bracket mounting boss is connected to the air filter mounting bracket by fixing bolts.

[0013] Furthermore, the transmission body is provided with multiple mounting seats, and the bottom of the housing assembly is provided with multiple mounting feet. Each of the multiple mounting seats corresponds to one of the multiple mounting feet, and the mounting seats and the corresponding mounting feet are fixedly connected by mounting bolts.

[0014] Furthermore, the number of mounting bases is greater than three, two of which are provided with positioning pins, and the bottom of the housing assembly is provided with two positioning holes, with the two positioning pins respectively connected to the two positioning holes.

[0015] Furthermore, there are two three-phase copper busbars, and there are correspondingly two high-voltage connector mounting channels and two three-phase high-voltage connectors.

[0016] The beneficial effects of this invention are: (1) The present invention extends into the high voltage connector installation channel through a three-phase high voltage connector, and the three-phase high voltage connector is directly connected to the three-phase copper busbar to realize the conduction of high voltage AC power, reduce the three-phase connection wiring harness and corresponding connectors, reduce costs, improve space utilization, and make the layout more compact. (2) The high voltage connector installation channel of the present invention is through the vertical direction, and the connection bolts can be disassembled and installed in the vertical direction to realize the separation or connection of the three-phase high voltage connector and the three-phase copper busbar. The disassembly and assembly are simple, avoiding the problem of poor assembly and maintenance process caused by the connection bolt disassembly and assembly space being blocked by other parts in the engine compartment. Furthermore, since the accuracy requirement of the bolt through hole of the three-phase copper busbar is low, the cumulative assembly tolerance of the motor controller body can be offset by the bolt through hole, reducing the requirements for product size tolerance and assembly accuracy, and further achieving the purpose of reducing production costs. (3) The sealing ring and the shielding layer of the three-phase high voltage connector of the present invention are both placed between the sealing end face and the base, realizing the gas-liquid sealing and electromagnetic shielding functions of the joint surface between the motor controller body and the three-phase high voltage connector, preventing external gas, liquid and solid impurities from entering the motor controller body from the high voltage connector installation channel, and also preventing the three-phase AC power from causing electromagnetic interference to the surrounding components. (4) The air filter mounting bracket of the present invention is detachable, and different air filter mounting brackets can be used to adapt to different air filter installation requirements, solve the installation requirements of air filters of different models, improve the universality of the layout structure, and facilitate the realization of product platform design. Attached Figure Description

[0017] To make the objectives, technical solutions, and beneficial effects of this invention clearer, the following figures are provided for illustration: Figure 1 This is an exploded view of the present invention; Figure 2 This is a cross-sectional schematic diagram of the connection between the three-phase copper busbar and the three-phase high-voltage connector of the present invention; Figure 3 This is a schematic diagram of the main body of the motor controller of the present invention; Figure 4 This is a top view of the main body of the motor controller of the present invention (the process cover has been removed for easier display). Figure 5 This is a bottom view of the main body of the motor controller of the present invention.

[0018] The following labels are shown in the attached diagram: 1-Motor controller body, 11-Main housing, 111-High voltage connector mounting channel, 112-Sealing end face, 113-Air filter bracket mounting boss, 114-Positioning hole, 115-Mounting foot, 12-Three-phase copper busbar, 13-Process cover plate, 14-Housing top cover; 2- Mounting bolts; 3- Connecting bolts; 4-Three-phase high-voltage connector, 41-Sealing ring, 42-Three-phase high-voltage connector shielding layer; 5-Air filter mounting bracket; 6-Transmission body; 61-Mounting seat; 7-Positioning pin; 8-Fixing bolt. Detailed Implementation

[0019] The technical solution of the present invention will be described in detail below with reference to the accompanying drawings and embodiments.

[0020] like Figures 1-5As shown in this embodiment, a low-cost, compact motor controller assembly structure for a hybrid vehicle includes a motor controller body 1 and a transmission body 6. The motor controller body 1 includes a housing assembly and a three-phase copper busbar 12. The housing assembly has a high-voltage connector mounting channel 111 extending vertically, and the three-phase copper busbar 12 extends into the high-voltage connector mounting channel 111. A three-phase high-voltage connector 4 is positioned on the transmission body 6 corresponding to the high-voltage connector mounting channel 111. The motor controller body 1 is connected to the transmission body 6, and the three-phase high-voltage connector 4 extends into the high-voltage connector mounting channel 111 and connects to the three-phase copper busbar 12. In this embodiment, the three-phase copper busbar 12 has bolt through holes, and the three-phase high-voltage connector 4 has threaded holes. Connecting bolts 3 pass through the bolt through holes and connect to the threaded holes, thereby connecting the three-phase copper busbar 12 to the three-phase high-voltage connector 4. Each three-phase copper busbar 12 is connected to its corresponding three-phase high-voltage connector 4 via three connecting bolts 3.

[0021] The three-phase high-voltage connector 4 extends into the high-voltage connector mounting channel 111 and is directly connected to the three-phase copper busbar 12, enabling the conduction of high-voltage AC power. This reduces the number of three-phase wiring harnesses and corresponding connectors, thereby lowering costs, improving space utilization, and making the layout more compact. Simultaneously, the high-voltage connector mounting channel 111 runs vertically, allowing for the removal and installation of the connecting bolts 3 in this direction to separate or connect the three-phase high-voltage connector 4 and the three-phase copper busbar 12. This simplifies assembly and avoids the problem of poor assembly and maintenance processes caused by other components in the engine compartment obstructing the space for bolt removal and installation. Furthermore, since the bolt holes of the three-phase copper busbar 12 have lower precision requirements, the cumulative assembly tolerance of the motor controller body 1 can be offset through these holes, reducing the requirements for product dimensional tolerances and overall assembly precision, further achieving the goal of reducing production costs.

[0022] In this embodiment, the three-phase high-voltage connector 4 includes a base and a connector head. The bottom of the base is connected to the gearbox body 6, and the connector head protrudes upward from the middle of the base. The connector head is used to extend into the high-voltage connector mounting channel 111.

[0023] In this embodiment, the three-phase high-voltage connector 4 further includes a sealing ring 41 surrounding the connector head. A sealing end face 112 is provided on the lower side of the housing assembly corresponding to the periphery of the high-voltage connector mounting channel 111. The upper surface of the sealing ring 41 is in close contact with the sealing end face 112, and the lower surface of the sealing ring 41 is in close contact with the base. In this embodiment, the three-phase high-voltage connector 4 also includes a three-phase high-voltage connector shielding layer 42 surrounding the sealing ring 41. The upper surface of the three-phase high-voltage connector shielding layer 42 is in close contact with the sealing end face 112, and the lower surface of the three-phase high-voltage connector shielding layer 42 is in close contact with the base. Both the sealing ring 41 and the three-phase high-voltage connector shielding layer 42 are placed between the sealing end face 112 and the base, achieving gas-liquid sealing and electromagnetic shielding functions at the mating surface of the motor controller body 1 and the three-phase high-voltage connector 4. This prevents external gas, liquid, and solid impurities from entering the motor controller body 1 from the high-voltage connector mounting channel 111, and also prevents electromagnetic interference from three-phase AC power to surrounding components.

[0024] In this embodiment, the housing assembly includes a main housing 11 and a housing cover 14 disposed on the upper side of the main housing 11. The high-voltage connector mounting channel 111 extends through both the housing cover 14 and the main housing 11 in the vertical direction. The housing cover 14 is provided with a process cover plate 13 for sealing the high-voltage connector mounting channel 111. The process cover plate 13 is removable and reassembled. The lower side of the process cover plate 13 has a built-in sealing structure. After the process cover plate 13 is installed, the high-voltage connector mounting channel 111 is sealed, and the process cover plate 13 can prevent external gas, liquid, and solid impurities from entering the high-voltage connector mounting channel 111. After removing the process cover plate 13, the high-voltage connector mounting channel 111 is exposed, and the connecting bolts 3 can be removed and installed in the vertical direction to separate or connect the three-phase high-voltage connector 4 and the three-phase copper busbar 12.

[0025] In this embodiment, an air filter mounting bracket 5 is also included. An air filter bracket mounting boss 113 is provided on the outside of the main housing 11. The air filter bracket mounting boss 113 is connected to the air filter mounting bracket 5 by fixing bolts 8. The air filter bracket mounting boss 113 on the outside of the main housing 11 provides an installation position for the air filter mounting bracket 5. The air filter mounting bracket 5 is detachable, allowing different air filter mounting brackets 5 to be used to adapt to different air filter installation needs, solving the installation requirements of air filters for different vehicle models, improving the versatility of the layout structure, and facilitating the realization of product platform design.

[0026] In this embodiment, the transmission body 6 is provided with a plurality of mounting seats 61, and the bottom of the housing assembly is provided with a plurality of mounting feet 115. The plurality of mounting seats 61 correspond one-to-one with the plurality of mounting feet 115, and the mounting seats 61 and the corresponding mounting feet 115 are fixedly connected by mounting bolts 2.

[0027] In this embodiment, the number of mounting bases 61 is greater than three, with two of the mounting bases 61 equipped with positioning pins 7. The bottom of the housing assembly has two positioning holes 114, and the two positioning pins 7 are respectively connected to the two positioning holes 114. The number of mounting bases 61 and mounting legs 115 is six. The positioning pins 7 on the mounting bases 61 ensure the positional accuracy between the positioning pins 7 and the mounting bases 61. This ensures that after the two positioning pins 7 are inserted into the two positioning holes 114, the holes on the mounting bases 61 correspond to those on the mounting brackets, facilitating the fixing of the mounting bases 61 and the mounting brackets with the mounting bolts 2. This prevents situations where manufacturing tolerances result in successful positioning but the mounting bases 61 and mounting legs 115 cannot be connected.

[0028] In this embodiment, two three-phase copper busbars 12 are provided, and two high-voltage connector mounting channels 111 and two three-phase high-voltage connectors 4 are also provided. Furthermore, two process cover plates 13 are also provided.

[0029] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A low-cost, compact motor controller assembly structure for hybrid vehicles, characterized in that: The system includes a motor controller body (1) and a transmission body (6); the motor controller body (1) includes a housing assembly and a three-phase copper busbar (12), the housing assembly has a high-voltage connector mounting channel (111) running vertically inside, and the three-phase copper busbar (12) extends into the high-voltage connector mounting channel (111); the transmission body (6) has a three-phase high-voltage connector (4) at a position corresponding to the high-voltage connector mounting channel (111); The motor controller body (1) is connected to the transmission body (6). The three-phase high-voltage connector (4) extends into the high-voltage connector mounting channel (111) and is connected to the three-phase copper busbar (12) by connecting bolts (3). The three-phase high-voltage connector (4) and the three-phase copper busbar (12) can be separated or connected by disassembling and assembling the connecting bolts (3) in the up and down direction. The three-phase high-voltage connector (4) includes a base, a connector head, and a sealing ring (41) surrounding the connector head. The bottom of the base is connected to the gearbox body (6), and the connector head protrudes upward from the middle of the base. A sealing end face (112) is provided on the lower side of the housing assembly corresponding to the periphery of the high-voltage connector mounting channel (111). The upper surface of the sealing ring (41) is in close contact with the sealing end face (112), and the lower surface of the sealing ring (41) is in close contact with the base.

2. The low-cost, compact motor controller assembly structure for hybrid vehicles according to claim 1, characterized in that: The three-phase high-voltage connector (4) also includes a three-phase high-voltage connector shielding layer (42) surrounding the outside of the sealing ring (41). The upper surface of the three-phase high-voltage connector shielding layer (42) is in close contact with the sealing end face (112), and the lower surface of the three-phase high-voltage connector shielding layer (42) is in close contact with the base.

3. The low-cost, compact motor controller assembly structure for hybrid vehicles according to claim 1, characterized in that: The three-phase copper busbar (12) is provided with bolt through holes, and the three-phase high-voltage connector (4) is provided with threaded holes. The connecting bolt (3) passes through the bolt through holes and connects with the threaded holes, so that the three-phase copper busbar (12) and the three-phase high-voltage connector (4) are connected.

4. The low-cost, compact motor controller assembly structure for hybrid vehicles according to claim 1, characterized in that: The housing assembly includes a main housing (11) and a housing cover (14) disposed on the upper side of the main housing (11). The high-voltage connector mounting channel (111) passes through the housing cover (14) and the main housing (11) in the vertical direction. The housing cover (14) is provided with a process cover plate (13) for sealing the high-voltage connector mounting channel (111).

5. The low-cost, compact motor controller assembly structure for hybrid vehicles according to claim 4, characterized in that: It also includes an air filter mounting bracket (5), and an air filter bracket mounting boss (113) is provided on the outside of the main housing (11). The air filter bracket mounting boss (113) is connected to the air filter mounting bracket (5) by fixing bolts (8).

6. The low-cost, compact motor controller assembly structure for hybrid vehicles according to claim 1, characterized in that: The transmission body (6) is provided with a plurality of mounting seats (61), and the bottom of the housing assembly is provided with a plurality of mounting feet (115). The plurality of mounting seats (61) correspond one-to-one with the plurality of mounting feet (115), and the mounting seats (61) and the corresponding mounting feet (115) are fixedly connected by mounting bolts (2).

7. The low-cost, compact motor controller assembly structure for hybrid vehicles according to claim 6, characterized in that: The number of mounting bases (61) is greater than three, two of which are provided with positioning pins (7), and the bottom of the housing assembly is provided with two positioning holes (114), and the two positioning pins (7) are respectively connected to the two positioning holes (114).

8. The low-cost, compact motor controller assembly structure for hybrid vehicles according to any one of claims 1-7, characterized in that: Two three-phase copper busbars (12) are provided, and two high-voltage connector mounting channels (111) and two three-phase high-voltage connectors (4) are provided respectively.

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