A vehicle-mounted drive motor controller

Abstract

The application discloses a vehicle-mounted driving motor controller, which comprises a shell, the shell is divided into a first cavity, a second cavity, a third cavity and a fourth cavity, a filter magnetic ring assembly is arranged in the first cavity, a film capacitor is arranged in the second cavity, a cooling plate is arranged in the third cavity, a SiC half-bridge module is arranged on the cooling plate, a three-phase switching fixed seat and a three-phase fixed seat are arranged in the fourth cavity, a first water inlet and a first water outlet are arranged on the lower end surface of the shell, a cooling water channel for the cooling liquid to flow into is arranged in the cooling plate, a second water inlet and a second water outlet are arranged on the side of the cooling plate away from the SiC half-bridge module, and the second water inlet and the second water outlet are communicated with the cooling water channel. The cooling liquid enters the cooling water channel in the cooling plate through the first water inlet and the second water inlet, the heat on the SiC half-bridge module is transmitted into the cooling water channel through the cooling plate, and the cooling liquid carries away the heat, so that the SiC half-bridge module can normally operate.

Description

Technical Field

[0001] This application relates to the field of controllers, and more particularly to an on-board drive motor controller. Background Technology

[0002] As one of the three core components of an electric vehicle, the motor controller obtains control over the motor from the overall vehicle control system to meet the requirements of starting, running, moving forward, and moving backward. The vehicle's power battery provides electrical energy, and the DC power obtained from the power battery is converted into the three-phase power required by the motor through an internal inverter, so that the motor's operating speed and torque meet the vehicle's requirements. It determines the excellent power performance of the entire vehicle.

[0003] As new energy vehicles are gradually promoted and applied, market acceptance of new energy is increasing. However, low driving range and slow charging have always been two major problems plaguing new energy vehicle owners and automakers. Currently, there are two ways to solve these problems: one is to increase battery driving range, and the other is to speed up charging. The 800V high-voltage SiC platform has emerged to address these issues, effectively improving battery charging speed, increasing overall vehicle operating efficiency, and extending driving range with the same battery capacity.

[0004] Currently, patent CN103872964A discloses a drive motor controller, including a housing and a control circuit board, an IPM drive module, a drive circuit board, an electrolytic capacitor, a current sensor, and a non-inductive filter capacitor installed inside the housing. It also includes a shielding iron plate installed in the middle of the housing. The drive circuit board is soldered to the IPM drive module and fixed inside the housing below the shielding iron plate. The control circuit board is fixed inside the housing above the shielding iron plate. A waterproof fan is provided at the center of the bottom of the housing, and strip-shaped heat sinks radiate outward from the center of the bottom of the housing, forming air ducts between the strip-shaped heat sinks.

[0005] Regarding the aforementioned related technologies, the inventors believe that the following defects exist: the drive motor controller only uses a waterproof fan for heat dissipation, which is not effective and can easily lead to high controller temperature, affecting the normal operation of the controller. Therefore, improvements are needed. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this application provides an on-board drive motor controller, which aims to solve the aforementioned problems.

[0007] A vehicle-mounted drive motor controller includes a housing, which is divided into a first chamber, a second chamber, a third chamber, and a fourth chamber. A filter magnetic ring assembly is installed in the first chamber, a thin-film capacitor is installed in the second chamber, a cooling plate is installed in the third chamber, a SiC half-bridge module is installed on the cooling plate, and a three-phase adapter and a three-phase mounting bracket are installed in the fourth chamber. A first water inlet and a first water outlet are provided on the lower end face of the housing. Cooling channels for coolant to flow into the cooling plate are provided inside the cooling plate. A second water inlet communicating with the first water inlet and a second water outlet communicating with the first water outlet are provided on the side of the cooling plate opposite to the SiC half-bridge module. Both the second water inlet and the second water outlet are connected to the cooling channels.

[0008] By adopting the above technical solution, the coolant enters the cooling water channel in the cooling plate through the first and second inlets. The heat on the SiC half-bridge module is transferred to the cooling water channel through the cooling plate, and the coolant carries away the heat, thereby ensuring that the SiC half-bridge module can operate normally. In addition, each functional component is modular and is installed in its respective chamber. The individual module components can be adjusted according to different customer needs, making the installation flexible and highly versatile.

[0009] Optionally, the SiC half-bridge module is provided with heat dissipation fins, and the cooling plate is provided with heat dissipation grooves for the heat dissipation fins to be inserted. The bottom wall of the heat dissipation groove is provided with a third water inlet and a third water outlet, both of which are connected to the cooling water channel.

[0010] By adopting the above technical solution, the coolant flows into the heat sink from the third inlet and then flows out from the third outlet. The SiC half-bridge module can transfer heat to the heat sink through the heat sink fins, and the coolant can carry away the heat on the heat sink fins, thereby improving the heat dissipation effect of the SiC half-bridge module.

[0011] Optionally, the cooling plate is detachably connected to the housing by bolts.

[0012] By adopting the above technical solution, people can pre-install the SiC half-bridge module on the cooling plate. When installing the cooling plate, it can be directly installed on the housing with bolts, which saves time and effort, and is easy to disassemble and maintain.

[0013] Optionally, a sealing ring groove is provided on the inner bottom wall of the shell at both the first water inlet and the first water outlet, and an elastic sealing ring is embedded in the sealing ring groove.

[0014] By adopting the above technical solution, the sealing ring is fitted into the sealing ring groove, and then the cooling plate is installed on the housing and the sealing ring is pressed tightly, thereby improving the sealing performance between the cooling plate and the housing.

[0015] Optionally, a drive board and a control board are also installed in the third chamber. The drive board is installed above the SiC half-bridge module, the SiC half-bridge module is connected to the lower end face of the drive board, and the control board is installed above the drive board.

[0016] By adopting the above technical solution, the third chamber consists of a control board, a drive board, and a SiC half-bridge module from top to bottom. This stacked design allows for a more compact layout within the housing.

[0017] Optionally, a shielding plate is installed between the drive board and the control board, and the four edges of the shielding plate are folded towards the control board.

[0018] By adopting the above technical solution, the shielding plate can isolate the drive board and the control board, isolate high and low harmonic interference, and make the internal system of the controller more stable.

[0019] Optionally, the shielding plate is provided with a plurality of support protrusions, each of which abuts against the control plate.

[0020] By adopting the above technical solution, the support protrusions on the shielding plate can provide support for the control board, thereby minimizing the risk of the control board breaking.

[0021] Optionally, an inlet pipe connected to the first water inlet is provided on the outer wall of the housing, and the inlet pipe is L-shaped.

[0022] By adopting the above technical solution, the L-shaped water inlet pipe can further reduce the size of the controller and facilitate installation.

[0023] Optionally, the outer wall of the shell is provided with a confluence channel, one end of which is connected to the first outlet and the other end of which is provided with a fourth outlet.

[0024] By adopting the above technical solution, on the one hand, the coolant flows into the manifold from the first outlet, and the manifold can slow down the flow rate of the coolant, thereby keeping the flow state of the coolant stable; on the other hand, since the manifold is set on the outer wall of the shell, the coolant can continue to cool the outer wall of the shell after flowing into the manifold, further improving the heat dissipation efficiency.

[0025] In summary, this application includes at least one of the following beneficial technical effects:

[0026] 1. Coolant enters the cooling channels within the cooling plate through the first and second inlets. Heat from the SiC half-bridge module is transferred to the cooling channels through the cooling plate, and the coolant carries away the heat, thus ensuring the normal operation of the SiC half-bridge module. In addition, each functional component is modular and installed in its respective chamber. Individual module components can be adjusted according to different customer needs, making installation flexible and highly versatile.

[0027] 2. The coolant flows into the heat sink from the third inlet and then flows out from the third outlet. The SiC half-bridge module can transfer heat to the heat sink through the heat sink fins. The coolant can carry away the heat on the heat sink fins, thereby improving the heat dissipation effect of the SiC half-bridge module.

[0028] 3. People can pre-install the SiC half-bridge module on the cooling plate. When installing the cooling plate, it can be directly installed on the housing with bolts, which saves time and effort, and is easy to disassemble and maintain.

[0029] 4. The third chamber consists of a control board, a drive board, and a SiC half-bridge module from top to bottom. This stacked design allows for a more compact layout within the housing.

[0030] 5. On the one hand, the coolant flows into the manifold from the first outlet. The manifold slows down the flow rate of the coolant, thus keeping the flow of the coolant stable. On the other hand, since the manifold is located on the outer wall of the shell, the coolant can continue to cool the outer wall of the shell after flowing into the manifold, further improving the heat dissipation efficiency. Attached Figure Description

[0031] Figure 1 This is a structural schematic diagram of an embodiment of this application.

[0032] Figure 2 This is a schematic diagram of the shell structure in an embodiment of this application.

[0033] Figure 3 This is an exploded view of an embodiment of this application.

[0034] Figure 4 This is a schematic diagram of the structure of the cooling plate in an embodiment of this application.

[0035] Figure 5 This is a schematic diagram of the cooling plate in the embodiment of this application from a bottom-view perspective.

[0036] Figure 6 This is a structural schematic diagram of the SiC half-bridge module in the embodiment of this application from a low angle, mainly used to show the structure of the heat dissipation fins.

[0037] Figure 7 This is a schematic diagram of the shell structure in the embodiment of this application from a bottom-view perspective.

[0038] Explanation of reference numerals in the attached figures:

[0039] 1. Housing; 11. First chamber; 12. Second chamber; 13. Third chamber; 131. Drive board; 132. Control board; 133. Shielding plate; 1331. Support protrusion; 14. Fourth chamber; 15. First water inlet; 16. First water outlet; 17. Sealing ring groove; 171. Sealing ring; 18. Water inlet pipe; 19. High voltage input plug; 2. Filter magnetic ring assembly; 3. Thin film capacitor; 4. Cooling plate; 41. Second water inlet; 42. Second water outlet; 43. Heat dissipation groove; 44. Third water inlet; 45. Third water outlet; 5. SiC half-bridge module; 51. Heat dissipation fins; 6. Three-phase adapter mounting base; 61. Three-phase mounting base; 7. Current sensor; 8. Combination channel; 81. Fourth water outlet. Detailed Implementation

[0040] To facilitate understanding of this application, a more detailed description is provided below with reference to the accompanying drawings and specific embodiments. It should be noted that when an element is described as "fixed to" another element, it can be directly on the other element, or one or more intermediate elements may exist between them. When an element is described as "connected to" another element, it can be directly connected to the other element, or one or more intermediate elements may exist between them. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this specification are for illustrative purposes only.

[0041] Unless otherwise defined, all technical and scientific terms used in this specification have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the scope of this application. The term "and / or" as used in this specification includes any and all combinations of one or more of the associated listed items.

[0042] This application discloses an on-board drive motor controller. (Refer to...) Figures 1 to 3The system includes a housing 1, whose internal space is divided into a first chamber 11, a second chamber 12, a third chamber 13, and a fourth chamber 14. A filter magnetic ring assembly 2 is installed in the first chamber. A thin-film capacitor 3 is installed in the second chamber 12. From top to bottom, a control board 132, a shielding plate 133, a drive board 131, and a cooling plate 4 are installed in the third chamber 13. Three SiC half-bridge modules 5 are welded to the lower end face of the drive board 131, and each SiC half-bridge module 5 is fixedly connected to the cooling plate 4. The cooling plate 4 is detachably connected to the housing 1 by bolts. A three-phase adapter mounting base 6, a current sensor 7, and a three-phase mounting base 61 are installed in the fourth chamber 14. A high-voltage input plug 19 is fixedly installed on the outer wall of the housing 1 near the first chamber 11, and the high-voltage input plug 19 is fixedly connected to the filter magnetic ring assembly 2.

[0043] The drive motor controller isolates the high and low voltages between the drive board 131 and the control board 132 through the shielding plate 133. The high voltage input plug-in 19 filters high-frequency harmonic interference through the secondary filter structure LCLC scheme of the filter magnetic ring assembly 2. After passing through the thin film capacitor 3 and the SiC half-bridge module 5, the current sensor 7 uses the Hall effect to pass the three-phase current wires through the magnetic core and measures the change in magnetic flux at the closed point of the magnetic core to detect the three-phase current. The controller detects and controls the three-phase current output current through the current sensor 7 to achieve the purpose of controlling the motor.

[0044] Reference Figures 2 to 5 The lower end face of the housing 1 has a first water inlet 15 and a first water outlet 16. The cooling plate 4 has cooling channels inside for coolant to flow into it. On the side of the cooling plate 4 opposite to the SiC half-bridge module 5, there is a second water inlet 41 connected to the first water inlet 15 and a second water outlet 42 connected to the first water outlet 16. Both the second water inlet 41 and the second water outlet 42 are connected to the cooling channels. Coolant enters the cooling channels within the cooling plate 4 through the first water inlet 15 and the second water inlet 41. Heat from the SiC half-bridge module 5 is transferred to the cooling channels through the cooling plate 4, and the coolant carries away the heat, thus ensuring the normal operation of the SiC half-bridge module 5.

[0045] Reference Figures 4 to 6The SiC half-bridge module 5 is fixedly connected to heat dissipation fins 51. The cooling plate 4 has heat dissipation grooves 43 for the heat dissipation fins 51 to fit into. The bottom wall of the heat dissipation groove 43 has a third inlet 44 and a third outlet 45, both of which are connected to cooling water channels. Coolant flows into the heat dissipation groove 43 from the third inlet 44 and then flows out from the third outlet 45. The SiC half-bridge module 5 transfers heat to the heat dissipation groove 43 through the heat dissipation fins 51, and the coolant carries away the heat from the heat dissipation fins 51, thereby improving the heat dissipation effect of the SiC half-bridge module 5. The SiC half-bridge module 5 can be pre-assembled with the cooling plate 4 as a whole on the production line, effectively improving assembly efficiency and reducing production costs.

[0046] Reference Figure 2 and Figure 3 Sealing ring grooves 17 are provided on the inner bottom wall of the housing 1 at the first water inlet 15 and the first water outlet 16. An elastic sealing ring 171 is embedded in the sealing ring groove 17. The sealing ring 171 is made of rubber. The sealing ring is fitted into the sealing ring groove 17, and then the cooling plate 4 is installed on the housing 1 and the sealing ring 171 is pressed tightly, thereby improving the sealing performance between the cooling plate 4 and the housing 1.

[0047] Reference Figure 3 The shielding plate 133 has its four edges folded towards the control plate 132, thus covering the drive plate 131. The shielding plate 133 isolates the drive plate 131 and the control plate 132, blocking high and low harmonic interference and making the internal system of the controller more stable. The shielding plate 133 has several support protrusions 1331, each of which abuts against the control plate 132. These support protrusions provide support for the control plate 132, thereby minimizing the risk of breakage.

[0048] Reference Figure 3 An inlet pipe 18, which communicates with the first water inlet 15, is fixedly connected to the outer wall of the housing 1. The inlet pipe 18 is L-shaped. The L-shaped inlet pipe 18 can further reduce the size of the controller and facilitate installation.

[0049] Reference Figure 2 and Figure 7 A manifold channel 8 is fixedly connected to the outer wall of the housing 1. One end of the manifold channel 8 is connected to the first outlet 16, and the other end has a fourth outlet 81. On the one hand, coolant flows into the manifold channel 8 from the first outlet 16. The manifold channel 8 can slow down the flow rate of the coolant, thereby keeping the flow state of the coolant stable. On the other hand, since the manifold channel 8 is located on the outer wall of the housing 1, the coolant can continue to cool the outer wall of the housing 1 after flowing into the manifold channel 8, further improving the heat dissipation efficiency.

[0050] The implementation principle of an on-board drive motor controller according to an embodiment of this application is as follows: coolant enters the cooling water channel in the cooling plate 4 through the first inlet 15 and the second inlet 41. The heat on the SiC half-bridge module 5 is transferred to the cooling water channel through the cooling plate 4. The coolant carries away the heat, thereby ensuring that the SiC half-bridge module 5 can operate normally. In addition, each functional component is modular and is installed in each cavity. The individual module components can be adjusted according to different customer needs, making the installation flexible and highly versatile.

[0051] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A vehicle-mounted drive motor controller, comprising a housing (1), characterized in that: The housing (1) is divided into a first chamber (11), a second chamber (12), a third chamber (13), and a fourth chamber (14). A filter magnetic ring assembly (2) is installed in the first chamber. A thin film capacitor (3) is installed in the second chamber (12). A cooling plate (4) is installed in the third chamber (13). A SiC half-bridge module (5) is installed on the cooling plate (4). A three-phase adapter fixing seat (6) and a three-phase fixing seat (61) are installed in the fourth chamber (14). A first water inlet (15) and a first water outlet (16) are provided on the lower end face of the housing (1). A cooling water channel for coolant to flow into the cooling plate (4) is provided inside the cooling plate (4). A second water inlet (41) connected to the first water inlet (15) and a second water outlet (42) connected to the first water outlet (16) are provided on the side of the cooling plate (4) away from the SiC half-bridge module (5). The second water inlet (41) and the second water outlet (42) are connected to the first water outlet (16). All ports (42) are connected to the cooling water channel. The SiC half-bridge module (5) is provided with heat dissipation fins (51). The cooling plate (4) is provided with a heat dissipation groove (43) for the heat dissipation fins (51) to be inserted. The bottom wall of the heat dissipation groove (43) is provided with a third water inlet (44) and a third water outlet (45). The third water inlet (44) and the third water outlet (45) are both connected to the cooling water channel. The third chamber (13) is also equipped with a drive plate ( The drive board (131) and control board (132) are mounted on top of the SiC half-bridge module (5). The SiC half-bridge module (5) is connected to the lower end face of the drive board (131). The control board (132) is mounted on top of the drive board (131). A shielding plate (133) is installed between the drive board (131) and the control board (132). The four edges of the shielding plate (133) are folded towards the control board (132).

2. The vehicle-mounted drive motor controller according to claim 1, characterized in that: The cooling plate (4) is detachably connected to the housing (1) by bolts.

3. The vehicle-mounted drive motor controller according to claim 1, characterized in that: Sealing ring grooves (17) are provided on the inner bottom wall of the housing (1) at the first water inlet (15) and the first water outlet (16), and an elastic sealing ring (171) is embedded in the sealing ring groove (17).

4. The vehicle-mounted drive motor controller according to claim 1, characterized in that: The shielding plate (133) is provided with a plurality of support protrusions (1331), each of which abuts against the control plate (132).

5. A vehicle-mounted drive motor controller according to claim 1, characterized in that: The outer wall of the housing (1) is connected to an inlet pipe (18) that communicates with the first inlet (15), and the inlet pipe (18) is L-shaped.

6. A vehicle-mounted drive motor controller according to claim 1, characterized in that: The outer wall of the shell (1) is provided with a confluence channel (8), one end of which is connected to the first outlet (16) and the other end is provided with a fourth outlet (81).

Images