Integrated inversion control device

Abstract

The invention relates to an integrated inversion control device, which is characterized in that a direct current input device, a direct current inversion module, a module control unit, a current detection module and a heat dissipation structure are integrated together, a mounting structure capable of highly utilizing space is designed, and the direct current inversion module comprises an integrated bottom plate, a support capacitor and a power module. The integrated bottom plate comprises an encapsulation groove, a support mounting flange and one or more cooling water grooves, and the supporting capacitor comprises a capacitor core, a capacitor input copper bar, a grounding copper bar, a Y capacitor, a capacitor output copper bar and a capacitor output end support. Through the design that the potting groove and the cooling water groove are oppositely arranged, the space utilization rate can be reduced, and meanwhile the heat dissipation effect is improved.

Description

Technical Field

[0001] The present invention relates to the field of electric drive, and in particular to an integrated inverter control device. Background Art

[0002] The motor controller is one of the key components of new energy vehicles. Taking the motor controller as the main body and integrating other vehicle components can improve the integration of the vehicle, realize the lightweight design of the vehicle, and reduce costs. Therefore, it is the future development trend of the motor controller. This kind of controller that integrates the functions of multiple components is generally called an all-in-one controller. The existing all-in-one controllers usually have poor integration between components because their internal components are usually not modularly designed.

[0003] For example, some all-in-one controllers integrate many devices such as motor controllers, power distributors, on-board chargers, DC bucks, etc. The assembly of such all-in-one controllers is complex, and the disassembly of inverter modules and their accessories is troublesome. The main problems caused by this are: 1) The compatibility of motor controllers is poor, and generally requires customized design based on the needs of the entire vehicle, which has high investment costs and long cycles; 2) Components are generally designed based on the box, and most of them are scattered in the box, with many assembly steps and a high error rate; 3) Due to the mutual mechanical connection between the components, disassembly is difficult. If you want to remove a component, you must first disassemble its related components one by one. Summary of the invention

[0004] The purpose of the present invention is to provide an integrated inverter control device, which integrates a DC input device, a DC inverter module, a module control unit and a current detection module, making the assembly process simpler. In order to adapt to the integration of these components, the design of the relative arrangement of the potting groove and the cooling water groove can save space utilization while improving the heat dissipation effect.

[0005] The purpose of the present invention can be achieved by the following technical solutions:

[0006] An integrated inverter control device comprises a DC input device, a DC inverter module, a module control unit, a current detection module and a mounting seat assembly, wherein the DC inverter module is arranged on the mounting seat assembly;

[0007] The DC inverter module includes an integrated base plate, a supporting capacitor and a power module. The integrated base plate includes a potting groove, a support mounting flange, and one or more cooling water grooves. The power module is arranged on the cooling water groove. The support mounting flange is arranged on a side of the potting groove close to the cooling water groove. The power module is also connected to the module control unit and the current detection module.

[0008] The supporting capacitor comprises a capacitor core, a capacitor input copper bar, a grounding copper bar, a Y capacitor, a capacitor output copper bar, and a capacitor output end support. The capacitor output end support is provided with a positioning groove engaged with the support mounting flange. The capacitor core and the Y capacitor are potted in the potting groove. The capacitor core is respectively connected to the capacitor input copper bar and the capacitor output copper bar. The Y capacitor is respectively connected to the capacitor input copper bar and the grounding copper bar. The capacitor input copper bar is also connected to a DC input device. The capacitor output copper bar passes through the support mounting flange and is connected to the input end of the power module and is fixed on the capacitor output end support.

[0009] The integrated bottom plate further comprises a shielding baffle, which encloses an inner cavity, the inner cavity is arranged adjacent to the potting groove, and the DC input device is arranged in the inner cavity.

[0010] The module control unit is stacked on the DC inverter module and is staggered with the potting groove.

[0011] The current detection module is arranged on the integrated bottom plate, and the current detection module and the potting groove are respectively located on two opposite sides of the cooling water groove.

[0012] The integrated base plate also includes a water inlet and a water outlet, and the DC inverter module also includes a water channel cover plate. The water channel cover plate and the cooling water channel are respectively located on two sides of the integrated base plate, and a water channel inlet and a water channel outlet are provided on the water channel cover plate. The water channel inlet is connected to the cooling water channel through the water inlet, and the water channel outlet is connected to the cooling water channel through the water outlet.

[0013] The water tank inlet and the water tank outlet are both waist-shaped through holes.

[0014] The water tank inlet and the water tank outlet are both provided with sealing grooves.

[0015] The DC inverter module further includes a first pressing plate and a second pressing plate, wherein the first pressing plate and the second pressing plate are located at two sides of the power module and press the power module onto the integrated bottom plate.

[0016] There are a plurality of positioning grooves, each of which is provided with a through hole, and the capacitor output copper bar passes through the support mounting flange and the through hole in sequence to connect to the input end of the power module.

[0017] The integrated base plate is also provided with heat dissipation ribs, which are arranged on the integrated base plate. The heat dissipation ribs and the potting groove are respectively located on both sides of the integrated base plate, and the projection area of ​​the heat dissipation ribs on the integrated base plate is located within the projection area of ​​the potting groove on the integrated base plate.

[0018] Compared with the prior art, the present invention has the following beneficial effects:

[0019] 1. The DC input device, DC inverter module, module control unit and current detection module are integrated, and the assembly process is simpler. In order to adapt to the integration of these components, the design of the relative setting of the potting tank and the cooling water tank can save space utilization and improve the heat dissipation effect.

[0020] 2. The design of the positioning groove being engaged with the support mounting flange on the integrated bottom plate during assembly can prevent the potting glue from overflowing from the matching gap between the capacitor output end support and the integrated bottom plate.

[0021] 3. The DC input device is located on the side of the potting tank and is wrapped with a shielding partition, which can improve the space utilization while improving the electromagnetic anti-interference ability.

[0022] 4. The module control unit is stacked on the DC inverter module and staggered with the potting slot, which can make the height direction more flat, improve the integration and space utilization, and reduce the line length, reduce the line resistance and reduce heat generation.

[0023] 5. The current detection module and the potting tank are located on opposite sides of the cooling water tank, so as to avoid interference caused by the proximity of the two and facilitate external connection of the current detection module.

[0024] 6. The capacitor core is potted inside the potting groove of the integrated base plate, and heat dissipation ribs are distributed at the bottom of the integrated base plate to dissipate heat from the capacitor core, resulting in a better temperature rise effect on the capacitor core. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a structural schematic diagram of the present invention;

[0026] Figure 2 Schematic diagram of the structure of a DC inverter module, wherein (a) is a top surface perspective, and (b) is a bottom surface perspective;

[0027] Figure 3 Schematic diagram of the structure of the integrated base plate, where (a) is the upper surface perspective, and (b) is the lower surface perspective;

[0028] Figure 4 It is a schematic diagram of the structure of the supporting capacitor;

[0029] Figure 5 It is a structural schematic diagram of the capacitor output terminal support;

[0030] Figure 6 It is a structural schematic diagram of the waterway cover;

[0031] Figure 7 is a schematic diagram of the structure of the mounting seat assembly;

[0032] Wherein: 1. DC input device, 2. DC inverter module, 3. module control unit, 4. current detection module, 5. mounting base assembly, 2-1. integrated base plate, 2-2. supporting capacitor, 2-3. power module, 2-4. first clamping plate, 2-5. second clamping plate, 2-6. water channel cover plate; 5-1. mounting base, 5-2. water pipe joint, 2-1-1. shielding partition, 2-1-2. potting groove, 2-1-3. support mounting flange, 2-1-4. sealing groove, 2-1-5. cooling water tank, 2-1-6. heat dissipation rib, 2-1 -7, water inlet, 2-1-8, water outlet, 2-2-1, capacitor core, 2-2-2, capacitor input copper busbar, 2-2-3, grounding copper busbar, 2-2-4, Y capacitor, 2-2-5, capacitor output copper busbar, 2-2-6, capacitor output end support, 2-6-1, water sink inlet, 2-6-2, water sink outlet, 2-6-3, sealing groove, 2-1-5-1, cooling water sink inlet, 2-1-5-2, cooling water sink outlet; 2-2-6-1, positioning groove, 2-2-6-2, through hole, 2-2-6-3, fixing hole. DETAILED DESCRIPTION

[0033] The present invention is described in detail below in conjunction with the accompanying drawings and specific embodiments. This embodiment is implemented based on the technical solution of the present invention, and provides a detailed implementation method and specific operation process, but the protection scope of the present invention is not limited to the following embodiments.

[0034] An integrated inverter control device, such as Figure 1 As shown, it includes a DC input device 1, a DC inverter module 2, a module control unit 3, a current detection module 4 and a mounting seat assembly 5, wherein the DC inverter module 2 is arranged on the mounting seat assembly 5, wherein the structure of the mounting seat assembly 5 is as shown in Figure 7 As shown, the mounting seat assembly 5 includes a mounting seat 5-1 and a water pipe connector 5-2, and the two water pipe connectors 5-2 are respectively mounted at both ends of the mounting seat 1;

[0035] like Figure 2 As shown, the DC inverter module 2 includes an integrated base plate 2-1, a support capacitor 2-2 and a power module 2-3. Figure 3 As shown, the integrated base plate 2-1 includes a potting groove 2-1-2, a support mounting flange 2-1-3, and one or more cooling water grooves 2-1-5. The power module 2-3 is arranged on the cooling water groove 2-1-5, and the support mounting flange 2-1-3 is arranged on a side of the potting groove 2-1-2 close to the cooling water groove 2-1-5. The power module 2-3 is also connected to the module control unit 3 and the current detection module 4;

[0036] like Figure 4As shown, the supporting capacitor 2-2 includes a capacitor core 2-2-1, a capacitor input copper bar 2-2-2, a grounding copper bar 2-2-3, a Y capacitor 2-2-4, a capacitor output copper bar 2-2-5, and a capacitor output end support 2-2-6. The capacitor output end support 2-2-6 is provided with a positioning groove 2-2-6-1 engaged with the support mounting flange 2-1-3. The capacitor core 2-2-1 and the Y capacitor 2-2-4 are potted in the potting groove 2-1-2 The capacitor core 2-2-1 is respectively connected to the capacitor input copper bus 2-2-2 and the capacitor output copper bus 2-2-5, the Y capacitor 2-2-4 is respectively connected to the capacitor input copper bus 2-2-2 and the grounding copper bus 2-2-3, the capacitor input copper bus 2-2-2 is also connected to the DC input device 1, and the capacitor output copper bus 2-2-5 passes through the support mounting flange 2-1-3 and is connected to the input end of the power module 2-3 and is fixed on the capacitor output end support 2-2-6.

[0037] The DC input device 1, the DC inverter module 2, the module control unit 3 and the current detection module 4 are integrated, and the assembly process is simpler. In order to adapt to the integration of these components, the design of the relative arrangement of the potting groove 2-1-2 and the cooling water groove 2-1-5 can save space utilization and improve the heat dissipation effect. And because of the high integration and compatibility, the modular design is adopted, and the test can be carried out separately without the need for an all-in-one controller.

[0038] The design of the positioning groove being engaged with the support mounting flange on the integrated bottom plate during assembly can prevent the potting glue from overflowing from the matching gap between the capacitor output end support and the integrated bottom plate.

[0039] In addition, in some embodiments, the packaging structure of the power module 2-3 can integrate different numbers or types of power chips, and thus have different voltages and power levels. Therefore, power modules of different specifications can be selected as needed to be compatible with controllers of different power levels and application requirements of high voltage 800V and medium voltage 400V without changing the structure of other parts. In addition, the number of power modules 2-3 can also be selected as needed, that is, not every cooling water tank 2-1-5 must be equipped with a power module 2-3.

[0040] The integrated base plate 2-1 also includes a shielding baffle 2-1-1, which encloses an inner cavity, which is adjacent to the potting groove 2-1-2, and the DC input device 1 is arranged in the inner cavity. The DC input device 1 is arranged on the side of the potting groove 2-1-2 and is wrapped by the shielding baffle 2-1-1, which can improve the electromagnetic interference resistance while improving the space utilization.

[0041] The module control unit 3 is stacked on the DC inverter module 2 and staggered with the potting groove 2-1-2, which can make the height direction flatter, improve integration and space utilization, and reduce line length, line resistance and heat generation.

[0042] The current detection module 4 is arranged on the integrated bottom plate 2-1, and the current detection module 4 and the potting groove 2-1-2 are respectively located on two opposite sides of the cooling water groove 2-1-5. The design that the current detection module 4 and the potting groove 2-1-2 are respectively located on two opposite sides of the cooling water groove 2-1-5 can avoid interference caused by the close proximity of the two, and facilitate the external connection of the current detection module 4.

[0043] The integrated bottom plate 2-1 also includes a water inlet trough 2-1-7 and a water outlet trough 2-1-8, and the DC inverter module 2 also includes a water channel cover plate 2-6. The water channel cover plate 2-6 and the cooling water trough 2-1-5 are respectively located on two sides of the integrated bottom plate 2-1, and as shown in FIG. Figure 6 As shown, a water channel cover plate 2-6 is provided with a water channel inlet 2-6-1 and a water channel outlet 2-6-2, the water channel inlet 2-6-1 is connected to the cooling water channel 2-1-5 through the water inlet 2-1-7, and the water channel outlet 2-6-2 is connected to the cooling water channel 2-1-5 through the water outlet 2-1-8. In addition, in this embodiment, there are three cooling water channels 2-1-5, each cooling water channel 2-1-5 includes one water inlet 2-1-5-1 and one water outlet 2-1-5-2, the water inlet 2-1-7 is connected to the three cooling water channel inlets 2-1-5-1, and the water outlet 2-1-8 is connected to the three cooling water channel outlets 2-1-5-2.

[0044] The water tank inlet 2-6-1 and the water tank outlet 2-6-2 are both waist-shaped through holes.

[0045] The water tank inlet 2-6-1 and the water tank outlet 2-6-2 are both provided with sealing grooves 2-6-3, and the sealing grooves 2-6-3 on the water tank inlet 2-6-1 and the water tank outlet 2-6-2 are both arranged around a circle.

[0046] The DC inverter module 2 further includes a first pressing plate 2-4 and a second pressing plate 2-5. The first pressing plate 2-4 and the second pressing plate 2-5 are located on both sides of the power module 2-3 and press the power module 2-3 onto the integrated base plate 2-1.

[0047] like Figure 5 As shown, there are a plurality of positioning grooves 2-2-6-1, each positioning groove 2-2-6-1 is provided with a through hole 2-2-6-2, and the capacitor output copper bus 2-2-5 passes through the support mounting flange 2-1-3 and the through hole 2-2-6-2 in sequence to connect to the input end of the power module 2-3.

[0048] The integrated bottom plate 2-1 is also provided with heat dissipation ribs 2-1-6, which are arranged on the integrated bottom plate 2-1. The heat dissipation ribs 2-1-6 and the potting groove 2-1-2 are respectively located on both sides of the integrated bottom plate 2-1, and the projection area of ​​the heat dissipation ribs 2-1-6 on the integrated bottom plate 2-1 is located within the projection area of ​​the potting groove 2-1-2 on the integrated bottom plate 2-1. The capacitor core is potted inside the potting groove of the integrated bottom plate, and the heat dissipation ribs 2-1-6 are distributed at the bottom of the integrated bottom plate to dissipate heat for the capacitor core, and the temperature rise effect of the capacitor core is good.

[0049] In addition, in this embodiment, the capacitor input copper bus 2-2-2 and the capacitor output copper bus 2-2-5 are respectively welded to the two end faces of the capacitor core 2-2-1, and the Y capacitor 2-2-4 is welded to the capacitor input copper bus 2-2-2 and the grounding copper bus 2-2-3. In addition to the capacitor core 2-2-1 and the Y capacitor 2-2-4 being potted in the potting groove 2-1-2 of the integrated base plate 2-1, part of the structure of the capacitor input copper bus 2-2-2, the grounding copper bus 2-2-3 and the capacitor output copper bus 2-2-5 is potted in the potting groove 2-1-2 of the integrated base plate 2-1, the input end of the capacitor input copper bus 2-2-2 is connected to the DC input device 1, and the output end of the capacitor output copper bus 2-2-5 is connected to the power module 2-3.

[0050] The assembly process of the device in this embodiment is as follows:

[0051] First, the capacitor input copper bus 2-2-2 and the capacitor output copper bus 2-2-5 in the supporting capacitor 2-2 are respectively welded to the capacitor core 2-2-1; the Y capacitor 2-2-4 in the supporting capacitor 2-2 is welded to the capacitor input copper bus 2-2-2 and the grounding copper bus 2-2-3.

[0052] Then, the capacitor output copper bus 2-2-5 in the supporting capacitor 2-2 is passed through the through hole 2-2-6-2 of the capacitor output end support 2-2-6, and then the capacitor output end support 2-2-6 is installed on the integrated base plate 2-1, and other components of the supporting capacitor 2-2 are also installed inside the potting groove of the integrated base plate 2-1.

[0053] Then, the capacitor core 2-2-1, capacitor input copper bus 2-2-2, grounding copper bus 2-2-3, Y capacitor 2-2-4, and capacitor output copper bus 2-2-5 in the supporting capacitor 2-2 are simultaneously potted in the potting groove 2-1-2 of the integrated base plate 2-1.

[0054] Then, the water channel cover plate 2-6 is welded to the bottom of the integrated base plate 2-1.

[0055] Then, the current detection module 4 is fixed on the integrated base plate 2 - 1 .

[0056] Then, three O-rings are sequentially installed in the sealing groove 2-1-4 of the integrated base plate 2-1. Three power modules 2-3 are sequentially installed above the cooling water tank 2-1-5 of the integrated base plate 2-1. The input terminals of the three power modules 2-3 are connected to the capacitor output copper bar 2-2-5 with screws, and the output terminals of the power modules 2-3 are connected to the current detection module 4 with screws.

[0057] Then, two first clamping plates 2-4 are installed between every two power modules 2-3, and two second clamping plates 2-5 are installed at one of the side positions of the two power modules 2-3 on both sides, and then the first clamping plates 2-4 and the second clamping plates 2-5 are fixed to the integrated base plate 2-1 with screws, and the power modules 2-3 are clamped simultaneously using the first clamping plates 2-4 and the second clamping plates 2-5.

[0058] Then, the DC input device 1 is fixed on the integrated bottom plate 2 - 1 .

[0059] Then, two water pipe joints 5 - 2 are press-fitted onto the mounting seat 5 - 1 to form the mounting seat assembly 5 .

[0060] Finally, the mounting seat assembly 5 is installed at the bottom of the integrated base plate 2-1, and the installation is completed.

Claims

1. An integrated inverter control device, characterized in that: It comprises a direct current input device (1), a direct current inverter module (2), a module control unit (3), a current detection module (4) and a mounting seat assembly (5), wherein the direct current inverter module (2) is arranged on the mounting seat assembly (5); The DC inverter module (2) comprises an integrated base plate (2-1), a supporting capacitor (2-2) and a power module (2-3); the integrated base plate (2-1) comprises a potting groove (2-1-2), a support mounting flange (2-1-3), and one or more cooling water grooves (2-1-5); the power module (2-3) is arranged on the cooling water groove (2-1-5); the support mounting flange (2-1-3) is arranged on a side of the potting groove (2-1-2) close to the cooling water groove (2-1-5); the power module (2-3) is also connected to the module control unit (3) and the current detection module (4); The supporting capacitor (2-2) comprises a capacitor core (2-2-1), a capacitor input copper bar (2-2-2), a grounding copper bar (2-2-3), a Y capacitor (2-2-4), a capacitor output copper bar (2-2-5) and a capacitor output end support (2-2-6); the capacitor output end support (2-2-6) is provided with a positioning groove (2-2-6-1) engaged with the support mounting flange (2-1-3); the capacitor core (2-2-1) and the Y capacitor (2-2-4) are potted in the potting groove (2-1-2). The capacitor core (2-2-1) is respectively connected to the capacitor input copper bar (2-2-2) and the capacitor output copper bar (2-2-5); the Y capacitor (2-2-4) is respectively connected to the capacitor input copper bar (2-2-2) and the grounding copper bar (2-2-3); the capacitor input copper bar (2-2-2) is also connected to the DC input device (1); the capacitor output copper bar (2-2-5) passes through the support mounting flange (2-1-3) and is connected to the input end of the power module (2-3) and is fixed on the capacitor output end support (2-2-6).

2. The integrated inverter control device according to claim 1, characterized in that: The integrated base plate (2-1) further comprises a shielding baffle (2-1-1), wherein the shielding baffle (2-1-1) encloses an inner cavity, the inner cavity is arranged adjacent to the potting groove (2-1-2), and the DC input device (1) is arranged in the inner cavity.

3. The integrated inverter control device according to claim 1, characterized in that: The module control unit (3) is stacked on the DC inverter module (2).

4. The integrated inverter control device according to claim 1, characterized in that: The current detection module (4) is arranged on the integrated base plate (2-1), and the current detection module (4) and the potting groove (2-1-2) are respectively located on two opposite sides of the cooling water groove (2-1-5).

5. The integrated inverter control device according to claim 1, characterized in that: The integrated base plate (2-1) further comprises a water inlet trough (2-1-7) and a water outlet trough (2-1-8), and the DC inverter module (2) further comprises a water channel cover plate (2-6), the water channel cover plate (2-6) and the cooling water trough (2-1-5) are respectively located on two side surfaces of the integrated base plate (2-1), and the water channel cover plate (2-6) is provided with a water trough inlet (2-6-1) and a water trough outlet (2-6-2), the water trough inlet (2-6-1) is connected to the cooling water trough (2-1-5) through the water inlet trough (2-1-7), and the water trough outlet (2-6-2) is connected to the cooling water trough (2-1-5) through the water outlet trough (2-1-8).

6. The integrated inverter control device according to claim 5, characterized in that: The water tank inlet (2-6-1) and the water tank outlet (2-6-2) are both waist-shaped through holes.

7. The integrated inverter control device according to claim 5, characterized in that: The water tank inlet (2-6-1) and the water tank outlet (2-6-2) are both provided with sealing grooves (2-6-3).

8. The integrated inverter control device according to claim 1, characterized in that: The DC inverter module (2) further comprises a first pressing plate (2-4) and a second pressing plate (2-5), wherein the first pressing plate (2-4) and the second pressing plate (2-5) are located on both sides of the power module (2-3) and press the power module (2-3) onto the integrated base plate (2-1).

9. The integrated inverter control device according to claim 1, characterized in that: A plurality of positioning grooves (2-2-6-1) are provided, each positioning groove (2-2-6-1) is provided with a through hole (2-2-6-2), and the capacitor output copper bar (2-2-5) passes through the support mounting flange (2-1-3) and the through hole (2-2-6-2) in sequence to connect to the input end of the power module (2-3).

10. The integrated inverter control device according to claim 1, characterized in that: The integrated base plate (2-1) is also provided with heat dissipation ribs (2-1-6), the heat dissipation ribs (2-1-6) are arranged on the integrated base plate (2-1), the heat dissipation ribs (2-1-6) and the potting groove (2-1-2) are respectively located on two sides of the integrated base plate (2-1), and the projection area of ​​the heat dissipation ribs (2-1-6) on the integrated base plate (2-1) is located within the projection area of ​​the potting groove (2-1-2) on the integrated base plate (2-1).

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