Temperature detection method and device for power module of motor controller in new energy vehicle

Abstract

This application discloses a method and apparatus for temperature detection of the power module of a new energy vehicle motor controller. The method includes: receiving the temperature of the upper heat sink copper plate of the power module; calculating the power loss of the power module and diodes based on the operating state of the motor controller; wherein the top surfaces of the diodes and the power module are in contact with the bottom surface of the upper heat sink copper plate; receiving the flow rate and temperature of the coolant entering the radiator of the power module; a medium is provided between the radiator and the power module; and calculating the actual temperature of the power module based on the temperature of the upper heat sink copper plate, the power loss of the power module and diodes, and the flow rate and temperature of the coolant. This application combines the temperature of the heat sink copper plate of the power module of the motor controller, the power loss of the power module and diodes, and the flow rate and temperature of the coolant to calculate the actual temperature of the power module, which can more accurately reflect the internal temperature of the power module.

Description

Technical Field

[0001] This application relates to the field of testing technology, and more specifically, to a method and apparatus for temperature detection of the power module of a new energy vehicle motor controller. Background Technology

[0002] In new energy vehicles, the power module is a crucial component, significantly impacting the vehicle's stability and safety. As the core device for energy conversion and transmission, the power module functions as the CPU within the motor controller MCU (MCU). Temperature control of the power module directly affects energy conversion efficiency and controller performance.

[0003] Because the thermal resistance of the power module is affected by the coolant flow rate, building a model solely based on the temperature value collected by the temperature sensor on the outer surface of the heat sink copper plate will result in low model accuracy, which may lead to two problems: First, if the temperature model is too conservative, the temperature limit during use will be too low, resulting in the motor controller's performance not being fully utilized and reducing energy conversion efficiency; Second, if the temperature model is too aggressive, the temperature limit during use will be too high, affecting the quality and lifespan of the motor controller. Summary of the Invention

[0004] This application provides a method and device for detecting the temperature of the power module of a new energy vehicle motor controller. By combining the temperature of the heat dissipation copper plate of the power module of the motor controller, the power loss of the power module and diodes, and the flow rate and temperature of the coolant, the actual temperature of the power module can be calculated. This method can more accurately reflect the internal temperature of the power module, ensuring that the performance of the controller can be fully utilized, while also protecting the quality and lifespan of the motor controller.

[0005] This application provides a method for temperature detection of the power module of a new energy vehicle motor controller, including:

[0006] Temperature of the upper heat sink copper plate of the receiving power module;

[0007] The power loss of the power module and diode is calculated based on the operating status of the motor controller; the top surfaces of both the diode and the power module are in contact with the bottom surface of the upper heat dissipation copper plate.

[0008] The flow rate and temperature of the coolant entering the radiator of the power module are received; a medium is provided between the radiator and the power module;

[0009] The actual temperature of the power module is calculated based on the temperature of the upper heat sink copper plate, the power loss of the power module and diodes, and the flow rate and temperature of the coolant.

[0010] Preferably, when calculating the actual temperature of the power module, the thermal resistance of the diode and the thermal resistance of the power module are determined based on the flow rate of the coolant; then, the actual temperature of the power module is calculated using the temperature of the upper heat sink copper plate, the power loss of the power module and the diode, the temperature of the coolant, the thermal resistance of the diode and the thermal resistance of the power module.

[0011] Preferably, calculating the actual temperature of the power module specifically includes:

[0012] Calculate the sum of the thermal resistance of the diode and the thermal resistance of the power module;

[0013] Calculate the product of the power loss of the power module and diodes and the sum of the power losses.

[0014] Calculate the mean of the sum of the squares of the coolant temperature and the temperature of the upper copper heat sink;

[0015] The sum of the product and the value obtained by taking the square root of the mean is used as the actual temperature of the power module.

[0016] Preferably, a lower heat dissipation copper plate is provided between the heat sink and the power module.

[0017] Preferably, thermal grease is provided between the heat sink and the lower heat dissipation copper plate.

[0018] This application also provides a temperature detection device for the power module of a new energy vehicle motor controller, including a first receiving module, a power calculation module, a second receiving module, and a first temperature calculation module;

[0019] The first receiving module is used to receive the temperature of the upper heat sink copper plate of the power module;

[0020] The power calculation module is used to calculate the power loss of the power module and diode based on the working status of the motor controller; the top surfaces of both the diode and the power module are in contact with the bottom surface of the upper heat dissipation copper plate.

[0021] The second receiving module is used to receive the flow rate and temperature of the coolant entering the radiator of the power module; a medium is provided between the radiator and the power module;

[0022] The first temperature calculation module is used to calculate the actual temperature of the power module based on the temperature of the upper heat sink copper plate, the power loss of the power module and diodes, and the flow rate and temperature of the coolant.

[0023] Preferably, the first temperature calculation module includes a thermal resistance determination module and a second temperature calculation module;

[0024] The thermal resistance determination module is used to determine the thermal resistance of the diode and the thermal resistance of the power module based on the flow rate of the coolant.

[0025] The second temperature calculation module is used to calculate the actual temperature of the power module using the temperature of the upper heat sink copper plate, the power loss of the power module and diode, the temperature of the coolant, the thermal resistance of the diode, and the thermal resistance of the power module.

[0026] Preferably, the second temperature calculation module includes a first sum calculation module, a product module, a mean calculation module, and a second sum calculation module;

[0027] The first calculation module is used to calculate the sum of the thermal resistance of the diode and the thermal resistance of the power module;

[0028] The product module is used to calculate the product of the power losses of the power module and diodes and the sum of the power losses.

[0029] The mean calculation module is used to calculate the mean of the sum of the squares of the coolant temperature and the temperature of the upper heat sink copper plate;

[0030] The second calculation module is used to calculate the sum between the product and the value obtained by taking the square root of the mean, which is used as the actual temperature of the power module.

[0031] Preferably, a lower heat dissipation copper plate is provided between the heat sink and the power module.

[0032] Preferably, thermal grease is provided between the heat sink and the lower heat dissipation copper plate.

[0033] Other features and advantages of this application will become clear from the following detailed description of exemplary embodiments with reference to the accompanying drawings. Attached Figure Description

[0034] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments of the present application and, together with their description, serve to explain the principles of the present application.

[0035] Figure 1 A flowchart of the temperature detection method for the power module of the new energy vehicle motor controller provided in this application;

[0036] Figure 2 A thermal resistance versus flow rate curve of one embodiment provided in this application;

[0037] Figure 3 The structural block diagram of the temperature acquisition system provided in this application;

[0038] Figure 4 for Figure 3 The diagram shows the control principle of the temperature acquisition system.

[0039] Figure 5 The diagram shows the structure of the temperature detection device for the power module of the new energy vehicle motor controller provided in this application. Detailed Implementation

[0040] Various exemplary embodiments of the present application will now be described in detail with reference to the accompanying drawings. It should be noted that, unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the present application.

[0041] The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the scope of this application and its application or use.

[0042] Techniques, methods, and equipment known to those skilled in the art may not be discussed in detail, but where appropriate, they should be considered part of the specification.

[0043] In all the examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values.

[0044] This application provides a method and device for temperature detection of the power module of a new energy vehicle motor controller. By combining the temperature of the heat dissipation copper plate of the power module of the motor controller, the power loss of the power module and diodes, and the flow rate and temperature of the coolant, the actual temperature of the power module can be calculated. This method can more accurately reflect the internal temperature of the power module, ensuring that the controller can fully perform, protecting the quality and life of the motor controller, and providing accurate input to the vehicle thermal management system, thereby improving the efficiency of the vehicle thermal management.

[0045] like Figure 1 As shown, the temperature detection method for the power module of the new energy vehicle motor controller provided in this application includes:

[0046] S110: Temperature T of the upper heat sink copper plate of the receiving power module 上板 .

[0047] S120: Calculates the power loss P of the power module and diodes based on the operating status of the motor controller. 损耗 The top surfaces of both the diodes and the power module are in contact with the bottom surface of the upper heat dissipation copper plate.

[0048] S130: Receives the flow rate Q of the coolant entering the heat sink (i.e., upstream of the heat sink) of the power module. 水 and temperature T 水 A medium is provided between the heat sink and the power module.

[0049] S140: Based on the temperature T of the upper heat sink copper plate 上板 Power loss P of power modules and diodes 损耗 and the flow rate Q of the coolant 水 and temperature T水 Calculate the actual temperature T of the power module 功率 .

[0050] The thermal resistance of the power module and diodes differs depending on the coolant flow rate, such as... Figure 2 As shown. Based on this, when calculating the actual temperature of the power module, the thermal resistance R of the diodes is determined according to the coolant flow rate. 二极管 Thermal resistance R of the power module 功率 Then, utilizing the temperature T of the upper copper heat sink... 上板 Power loss P of power modules and diodes 损耗 The temperature of the coolant, T 水 The thermal resistance R of the diode 二极管 The thermal resistance R of the power module 功率 Calculate the actual temperature T of the power module 功率 .

[0051] Specifically, utilizing the temperature T of the upper heat sink copper plate 上板 Power loss P of power modules and diodes 损耗 The temperature of the coolant, T 水 The thermal resistance R of the diode 二极管 The thermal resistance R of the power module 功率 Calculate the actual temperature T of the power module 功率 Specifically, it includes:

[0052] P1: Calculate the thermal resistance R of the diode. 二极管 The thermal resistance R of the power module 功率 The sum of.

[0053] P2: Calculate the power loss of the power module and diodes. 损耗 The product of the sum and the product of the two.

[0054] P3: Calculate the coolant temperature T 水 The temperature T of the heat sink copper plate 上板 The mean of the sum of squares.

[0055] P4: Calculate the sum between the product and the value obtained by taking the square root of the mean, and use this as the actual temperature T of the power module. 功率 .

[0056] Based on the above embodiments,

[0057] As an example, such as Figure 3 As shown, the temperature acquisition system includes a diode 5, an upper heat dissipation copper plate 4, a first temperature sensor 3, a heat sink 9, and a flow sensor 7 and a second temperature sensor 8 installed on the coolant pipeline upstream of the heat sink 9. A medium is provided between the heat sink 9 and the power module 2.

[0058] In one embodiment, the dielectric includes a lower heat dissipation copper plate 1. The power module 2 and diode 5 are placed at intervals on a horizontal plane, with their top and bottom surfaces respectively attached to the upper and lower heat dissipation copper plates 4 and 1. Diode 5 is used for signal rectification and freewheeling, consuming the current generated by the back electromotive force, thereby ensuring the safety of other components in the circuit. The upper heat dissipation copper plate 4 is fixedly connected to a first temperature sensor 3 to help the power module 2 dissipate heat from above. The first temperature sensor 3 is used to collect the temperature T of the upper heat dissipation copper plate 4. 上板 The lower heat dissipation copper plate 1 is used to fix the power module 2 and the diode 5, and to help the power module 2 dissipate heat from the bottom.

[0059] Preferably, the medium also includes thermal grease 6 between the heat sink and the lower heat sink copper plate, used to conduct heat from the lower heat sink copper plate 1 to the heat sink 9.

[0060] The flow sensor 7 and the second temperature sensor 8 are used to collect the flow rate and temperature of the coolant entering the radiator 9 in real time.

[0061] When the motor controller is working, the temperature of the power module 2 rises rapidly. Heat is transferred outward through the upper heat sink copper plate 4, and the temperature of the upper heat sink copper plate 4 can be directly collected by the first temperature sensor 3. The coolant flows through the coolant pipeline, through the second temperature sensor 8 and the flow sensor 7, into the heat sink 9, and cools the power module 2 through the thermal grease 6 and the lower heat sink copper plate 1.

[0062] like Figure 4 As shown, the motor controller (MCU) receives the temperature T of the upper heat sink copper plate from the first temperature sensor. 上板 The coolant flow rate Q collected by the flow sensor 水 The vehicle control unit (VCU) receives the coolant temperature T from the second temperature sensor 8. 水 This data is then transmitted to the MCU, which combines this data with its own calculations to obtain the power loss P of the power module and diodes. 损耗 Temperature T of the upper copper heat sink 上板 Coolant flow rate Q 水 and temperature T 水 Calculate the actual temperature T of the power module 功率 And based on the actual temperature T 功率 The MCU controls the motor's power and torque, while simultaneously transmitting the actual temperature T. 功率 The data is transmitted to the VCU, allowing the VCU to adjust the power module's temperature based on the actual temperature T. 功率 The system submits a thermal management request to the thermal management module, which then sends a corresponding duty cycle signal to the water pump to control it.

[0063] Based on the above temperature detection method, this application also provides a temperature detection device for the power module of a new energy vehicle motor controller. For example... Figure 5 As shown, the temperature detection device includes a first receiving module 510, a power calculation module 520, a second receiving module 530, and a first temperature calculation module 540.

[0064] The first receiving module 510 is used to receive the temperature of the upper heat sink copper plate of the power module.

[0065] The power calculation module 520 is used to calculate the power loss of the power module and diode based on the operating status of the motor controller. The top surfaces of both the diode and the power module are in contact with the bottom surface of the upper heat dissipation copper plate.

[0066] The second receiving module 530 is used to receive the flow rate and temperature of the coolant entering the radiator of the power module. A medium is provided between the radiator and the power module.

[0067] The first temperature calculation module 540 is used to calculate the actual temperature of the power module based on the temperature of the upper heat sink copper plate, the power loss of the power module and diode, and the flow rate and temperature of the coolant.

[0068] Preferably, the first temperature calculation module 540 includes a thermal resistance determination module 5401 and a second temperature calculation module 5402.

[0069] The thermal resistance determination module 5401 is used to determine the thermal resistance of the diode and the thermal resistance of the power module based on the flow rate of the coolant.

[0070] The second temperature calculation module 5402 is used to calculate the actual temperature of the power module using the temperature of the upper heat sink copper plate, the power loss of the power module and diode, the temperature of the coolant, the thermal resistance of the diode and the thermal resistance of the power module.

[0071] Preferably, the second temperature calculation module 5402 includes a first sum calculation module, a product module, a mean calculation module, and a second sum calculation module.

[0072] The first calculation module is used to calculate the sum of the thermal resistance of the diode and the thermal resistance of the power module.

[0073] The product module is used to calculate the product of the power losses of the power module and diodes.

[0074] The mean calculation module is used to calculate the mean of the sum of the squares of the coolant temperature and the temperature of the upper heat dissipation copper plate.

[0075] The second calculation module is used to calculate the sum between the product and the value obtained by taking the square root of the mean, which is used as the actual temperature of the power module.

[0076] Preferably, a lower heat dissipation copper plate is provided between the heat sink and the power module.

[0077] Preferably, thermal grease is provided between the heat sink and the lower heat dissipation copper plate.

[0078] While specific embodiments of this application have been described in detail by way of examples, those skilled in the art should understand that the above examples are for illustrative purposes only and are not intended to limit the scope of this application. Those skilled in the art should understand that modifications can be made to the above embodiments without departing from the scope and spirit of this application. The scope of this application is defined by the appended claims.

Claims

1. A method for detecting the temperature of the power module of a new energy vehicle motor controller, characterized in that, include: Temperature of the upper heat sink copper plate of the receiving power module; The power loss of the power module and diode is calculated based on the operating status of the motor controller; wherein the top surfaces of the diode and the power module are in contact with the bottom surface of the upper heat dissipation copper plate; The flow rate and temperature of the coolant entering the radiator of the power module are received; a medium is provided between the radiator and the power module; Based on the temperature of the upper heat dissipation copper plate, the power loss of the power module and diode, and the flow rate and temperature of the coolant, the actual temperature of the power module is calculated. Specifically, when calculating the actual temperature of the power module, the thermal resistance of the diode and the thermal resistance of the power module are determined based on the flow rate of the coolant. Then, the actual temperature of the power module is calculated using the temperature of the upper heat dissipation copper plate, the power loss of the power module and diode, the temperature of the coolant, the thermal resistance of the diode, and the thermal resistance of the power module. Calculate the sum of the thermal resistance of the diode and the thermal resistance of the power module; Calculate the product of the power loss of the power module and the diode and the sum; Calculate the mean of the sum of the squares of the temperatures of the coolant and the upper heat dissipation copper plate; The sum of the product and the value obtained by taking the square root of the mean is used as the actual temperature of the power module.

2. The temperature detection method for the power module of the new energy vehicle motor controller according to claim 1, characterized in that, A lower heat dissipation copper plate is provided between the heat sink and the power module.

3. The temperature detection method for the power module of the new energy vehicle motor controller according to claim 2, characterized in that, Thermal grease is provided between the heat sink and the lower heat dissipation copper plate.

4. A temperature detection device for the power module of a new energy vehicle motor controller, characterized in that, It includes a first receiving module, a power calculation module, a second receiving module, and a first temperature calculation module; The first receiving module is used to receive the temperature of the upper heat dissipation copper plate of the power module; The power calculation module is used to calculate the power loss of the power module and the diode based on the working state of the motor controller; wherein the top surfaces of the diode and the power module are both in contact with the bottom surface of the upper heat dissipation copper plate; The second receiving module is used to receive the flow rate and temperature of the coolant entering the radiator of the power module; a medium is provided between the radiator and the power module; The first temperature calculation module is used to calculate the actual temperature of the power module based on the temperature of the upper heat dissipation copper plate, the power loss of the power module and the diode, and the flow rate and temperature of the coolant; wherein, the first temperature calculation module includes a thermal resistance determination module and a second temperature calculation module; The thermal resistance determination module is used to determine the thermal resistance of the diode and the thermal resistance of the power module based on the flow rate of the coolant. The second temperature calculation module is used to calculate the actual temperature of the power module using the temperature of the upper heat dissipation copper plate, the power loss of the power module and the diode, the temperature of the coolant, the thermal resistance of the diode and the thermal resistance of the power module; and the second temperature calculation module includes a first sum calculation module, a product module, a mean calculation module and a second sum calculation module; The first calculation module is used to calculate the sum of the thermal resistance of the diode and the thermal resistance of the power module; The product module is used to calculate the product of the power loss of the power module and the diode and the sum; The mean calculation module is used to calculate the mean of the sum of the squares of the temperature of the coolant and the temperature of the upper heat dissipation copper plate; The second sum calculation module is used to calculate the sum between the product and the value obtained by taking the square root of the mean, which is taken as the actual temperature of the power module.

5. The temperature detection device for the power module of the new energy vehicle motor controller according to claim 4, characterized in that, A lower heat dissipation copper plate is provided between the heat sink and the power module.

6. The temperature detection device for the power module of the new energy vehicle motor controller according to claim 5, characterized in that, Thermal grease is provided between the heat sink and the lower heat dissipation copper plate.

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