Motor controller, electric driving device and vehicle

Abstract

The invention provides a motor controller, an electric driving device and a vehicle, the motor controller is used for inputting an external input signal into a battery structure and a motor of the electric driving device, and the motor controller comprises a shell, an integrated capacitor assembly, a filter inductor, a power assembly, a connecting copper bar assembly and a circuit board, the integrated capacitor assembly, the filter inductor and the power assembly are electrically connected through the copper bar assembly and the circuit board to form a boost charging filter loop and a driving loop, the integrated capacitor assembly, the filter inductor, the power assembly, the connecting copper bar assembly and the circuit board are all arranged in the shell, and the connecting copper bar assembly comprises an input copper bar and an output copper bar. The input copper bar is used for introducing an external input signal, and the output copper bar is connected with the motor and the speed reducer. According to the motor controller, the electric driving device and the vehicle, the space occupied by the boost charging device can be reduced, and therefore the manufacturing cost of the whole vehicle is reduced.

Description

Technical Field

[0001] The present application relates to the field of vehicle technology, and in particular to a motor controller, an electric drive device and a vehicle. Background Art

[0002] The electric drive device of an electric vehicle usually includes a motor, a reducer and a motor controller. With the development of supercharging technology, the electric drive technology of the 800V voltage system is gradually being promoted. In order to be compatible with the charging facilities of the 400V voltage platform on the market, a boost charging device needs to be added to the electric drive device so that the 400V charging facilities can charge the power battery of the 800V system after passing through the boost charging device.

[0003] However, the current boost charging device is an independent device that integrates components such as input filters and relays, and is connected to the vehicle's electric drive device and DC charging interface through a wiring harness. However, due to the limited interior space of the vehicle, the independently installed boost charging device is large in size and requires independent space in the vehicle for installation, which occupies the interior space of the vehicle and increases the manufacturing cost of the entire vehicle. Summary of the invention

[0004] The motor controller, electric drive device and vehicle provided in the present application can reduce the space occupied by the boost charging device, thereby reducing the manufacturing cost of the entire vehicle.

[0005] The present application provides a motor controller, wherein the motor controller is used to pass external input signals into a battery structure and a motor of an electric drive device. The motor controller includes a housing, an integrated capacitor assembly, a filter inductor, a power assembly, a connecting copper bus assembly and a circuit board. The integrated capacitor assembly, the filter inductor and the power assembly are electrically connected through the copper bus assembly and the circuit board to form a boost charging filter circuit and a drive circuit. The integrated capacitor assembly, the filter inductor, the power assembly, the connecting copper bus assembly and the circuit board are all arranged in the housing. The connecting copper bus assembly includes an input copper bus and an output copper bus. The input copper bus is used to pass the external input signal, and the output copper bus is connected to the motor and the reducer.

[0006] As above, the motor controller, wherein the integrated capacitor assembly includes a plurality of filter X capacitor cores, a plurality of filter Y capacitor cores, a first bus capacitor core and a plurality of second bus capacitor cores, the plurality of filter X capacitor cores, the first bus capacitor core and the filter inductor are electrically connected through a copper bus assembly and a circuit board to form a boost charging loop; the plurality of filter Y capacitor cores, the plurality of second bus capacitor cores and the filter inductor are electrically connected through a copper bus assembly and a circuit board to form a filter loop.

[0007] In the motor controller as above, a connecting harness is provided inside the circuit board, the circuit board cover is provided on the integrated capacitor assembly, and a plurality of filter X capacitor cores, a plurality of filter Y capacitor cores, a first bus capacitor core, a plurality of second bus capacitor cores and the filter inductor are connected through a connecting harness inside the circuit board.

[0008] As above, the connecting copper bar assembly includes an input copper bar, a negative bus copper bar, a positive bus copper bar and an output copper bar. The input copper bar is used to pass an external input signal. The filter inductor is electrically connected to the negative bus copper bar through the input copper bar. The negative bus copper bar cover is arranged on the negative electrode of the integrated capacitor assembly and is electrically connected to the negative electrode of the integrated capacitor assembly. The positive bus copper bar cover is arranged on the positive electrode of the integrated capacitor assembly and is electrically connected to the positive electrode of the integrated capacitor assembly. The input end of the power assembly is electrically connected to the positive bus copper bar and the negative bus copper bar. The output end of the power assembly is electrically connected to the output copper bar, and the output copper bar is electrically connected to the motor.

[0009] As the motor controller above, the connecting copper busbar assembly also includes a boost charging copper busbar, which is electrically connected to the positive electrode of the integrated capacitor assembly. The boost charging copper busbar has a relay connection port, and the relay assembly of the electric drive device is electrically connected to the boost charging copper busbar through the relay connection port.

[0010] As above motor controller, wherein the input copper bar includes a positive input copper bar, a negative input copper bar and a boost charging input copper bar, the positive input copper bar is electrically connected to the positive bus copper bar, the negative input copper bar is electrically connected to the negative bus copper bar, and the boost charging input copper bar is electrically connected to the boost charging copper bar.

[0011] As the motor controller above, the positive busbar copper bus has a protruding positive connection terminal, the negative busbar copper bus has a protruding negative connection terminal, the boost charging copper bus has a protruding boost charging connection terminal, and the positive connection terminal, the negative connection terminal and the boost charging connection terminal are all extended toward the direction of the input copper bus and are electrically connected to the input copper bus.

[0012] As in the motor controller above, the power component includes three half-bridge power modules, the output copper bus includes three copper buses for outputting three-phase electricity, and the three half-bridge power modules are connected to the three copper buses of the output copper bus in a one-to-one correspondence.

[0013] As above, the motor controller further includes a water cooling plate, which is installed between the integrated capacitor component and the power component for cooling the integrated capacitor component and the power component.

[0014] As above, the motor controller further includes a fixed insulating layer, which is encapsulated between the integrated capacitor assembly and the water cooling plate and is used to fix the integrated capacitor assembly, the filter inductor and the connecting copper busbar assembly.

[0015] As above, the motor controller further includes a high-voltage connector terminal, an adapter assembly and a signal connector terminal, wherein the output end of the high-voltage connector terminal is electrically connected to the input copper busbar through the adapter assembly, and the input end of the high-voltage connector terminal is used to receive an external high-voltage signal; the output end of the signal connector terminal is electrically connected to the relay assembly of the electric drive device, and the input end of the signal connector terminal is used to receive an external control signal, and the control signal can turn on or off the relay assembly.

[0016] On the other hand, the present application also provides an electric drive device, wherein the electric drive device includes the above-mentioned motor controller, and the electric drive device also includes a connected motor, a reducer and a relay assembly, the relay assembly includes a relay connecting copper bus and a relay, the relay is electrically connected to the motor controller through the relay connecting copper bus, and the relay is also electrically connected to the motor and the reducer to form a boost charging filter circuit and a drive circuit.

[0017] On the other hand, the present application also provides a vehicle, wherein the vehicle includes the above-mentioned electric drive device.

[0018] The motor controller of the present application includes a housing, an integrated capacitor assembly, a filter inductor, a power assembly, a connecting copper bus assembly and a circuit board, and the integrated capacitor assembly, the filter inductor, the power assembly, the connecting copper bus assembly and the circuit board are all arranged inside the housing, and the integrated capacitor assembly, the filter inductor and the power assembly are electrically connected by connecting the copper bus assembly and the circuit board to form a boost charging filter circuit and a drive circuit, the boost charging filter circuit can realize the boost charging function of the battery structure, and the drive circuit can drive the motor to work. Relative to the independently arranged boost charging device, the motor controller in the present application integrates the components required for the boost charging filter circuit constituting the drive circuit and the boost charging device into a housing, which is equivalent to integrating the boost charging device into the motor controller used only for driving the motor, reducing the space occupied by the boost charging device, thereby reducing the manufacturing cost of the whole vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 An exploded view of an electric drive device provided in an embodiment of the present application;

[0020] Figure 2 A top view of a motor controller provided in an embodiment of the present application;

[0021] Figure 3 An overall exploded diagram of a motor controller provided in an embodiment of the present application;

[0022] Figure 4 An exploded diagram of an integrated capacitor assembly of a motor controller provided in an embodiment of the present application;

[0023] Figure 5 A schematic diagram of packaging a fixed insulating layer of a motor controller provided in an embodiment of the present application;

[0024] Figure 6 A schematic diagram of the structure of a housing of a motor controller provided in an embodiment of the present application;

[0025] Figure 7 A partial exploded diagram of a motor controller provided in an embodiment of the present application;

[0026] Figure 8 A top view of an integrated capacitor assembly of a motor controller provided by an embodiment of the present application;

[0027] Fig. 9 A bottom view of an integrated capacitor assembly of a motor controller provided in an embodiment of the present application.

[0028] Description of Figure Numbers:

[0029] 10. Shell; 11. Water pipe joint; 12. High voltage input port; 13. Signal input port; 20. Integrated capacitor assembly; 21. Filter X capacitor core; 22. Filter Y capacitor core; 221. Grounding terminal; 222. Grounding screw; 23. First busbar capacitor core; 24. Second busbar capacitor core; 25. Insulation seat; 26. Insulation paper; 30. Filter inductor; 40. Power assembly; 50. Connecting copper bar assembly; 51. Input copper bar; 511. Positive input copper bar; 512. Negative input copper bar; 513. Boost charging Input copper busbar; 52, negative busbar copper busbar; 521, negative connection terminal; 522, negative welding part; 53, positive busbar copper busbar; 531, positive connection terminal; 532, positive welding part; 54, output copper busbar; 55, boost charging copper busbar; 551, relay connection port; 552, boost charging connection terminal; 56, positive connection copper busbar; 57, negative connection copper busbar; 60, circuit board; 61, shielding cover; 70, water cooling plate; 80, fixed insulation layer; 90, high voltage connector terminal; 91, adapter assembly; 92, signal connector terminal;

[0030] 100, motor controller; 200, motor; 300, reducer; 400, relay assembly; 410, relay connecting copper busbar; 420, relay. DETAILED DESCRIPTION

[0031] In order to more clearly understand the above-mentioned objectives, features and advantages of the present disclosure, the scheme of the present disclosure will be further described below. It should be noted that the embodiments of the present disclosure and the features in the embodiments can be combined with each other without conflict.

[0032] In the following description, many specific details are set forth to facilitate a full understanding of the present disclosure, but the present disclosure may also be implemented in other ways different from those described herein; it is obvious that the embodiments in the specification are only part of the embodiments of the present disclosure, rather than all of the embodiments.

[0033] like Figures 1 to 9 As shown, an embodiment of the present application provides a motor controller, wherein the motor controller 100 is used to pass an external input signal into a battery structure and a motor 200 of an electric drive device, and the motor controller 100 includes a housing 10, an integrated capacitor assembly 20, a filter inductor 30, a power assembly 40, a connecting copper bus assembly 50 and a circuit board 60, wherein the integrated capacitor assembly 20, the filter inductor 30 and the power assembly 40 are electrically connected via the connecting copper bus assembly 50 and the circuit board 60 to form a boost charging filter circuit and a drive circuit, wherein the boost charging filter circuit is connected to the battery structure, and can boost the main voltage signal in the external input signal to achieve a charging effect on the battery structure; the drive circuit is connected to the motor 200, and can drive the motor 200 to work. The integrated capacitor assembly 20, the filter inductor 30, the power assembly 40, the connecting copper busbar assembly 50 and the circuit board 60 are all arranged in the housing 10. Compared with the independently arranged boost charging device, the motor controller in the present application integrates the components required for the drive circuit and the boost charging filter circuit of the boost charging device into one housing 10, which is equivalent to integrating the boost charging device into the motor controller used only for driving the motor 200, thereby reducing the space occupied by the boost charging device and thus reducing the manufacturing cost of the entire vehicle.

[0034] It should be noted that the battery structure is connected to the boost charging filter circuit in the motor controller 100. Figure 1 Only the structures of the motor controller 100 and the motor 200 are shown, and the battery structure is not shown.

[0035] Specifically, the external input signal includes a main voltage signal and a control voltage signal. The control voltage signal is used to switch the boost charging filter circuit and the drive circuit, and the main voltage signal is used to provide voltage for the boost charging filter circuit and the drive circuit so that the boost charging filter circuit and the drive circuit can perform their respective functions.

[0036] like Figure 4As shown, the motor controller of the embodiment of the present application, wherein the integrated capacitor assembly 20 includes a plurality of filter X capacitor cores 21, a plurality of filter Y capacitor cores 22, a first bus capacitor core 23 and a plurality of second bus capacitor cores 24, and the plurality of filter X capacitor cores 21, the first bus capacitor core 23 and the filter inductor 30 are electrically connected by connecting the copper bar assembly 50 and the circuit board 60 to form a boost charging circuit; the plurality of filter Y capacitor cores 22, the plurality of second bus capacitor cores 24 and the filter inductor 30 are electrically connected by connecting the copper bar assembly 50 and the circuit board 60 to form a filter circuit. The boost charging circuit and the filter circuit are both electrically connected by connecting the copper bar assembly 50 and the circuit board 60, so that the connection between the integrated capacitor assembly 20 and the filter inductor 30 is more concise, reducing the space occupied by the entire circuit, thereby reducing the space occupied by the motor controller and reducing the manufacturing cost of the whole vehicle.

[0037] In a specific implementation, the boost charging filter circuit includes a boost charging circuit and a filter circuit. The boost charging circuit and the filter circuit work together to boost the main voltage signal, convert it into a high-voltage signal, and enable the high-voltage signal to be input into the battery structure to safely charge the battery structure.

[0038] Specifically, each capacitor in the integrated capacitor assembly 20 is a thin film capacitor winding core, and each capacitor is connected to the copper busbar assembly 50 and the gold sprayed layer of the capacitor core by soldering, thereby eliminating the leads between the integrated capacitor assembly 20 and the connecting copper busbar assembly 50, and between the capacitor cores of the integrated capacitor assembly 20; and the integrated capacitor assembly 20 and the connecting copper busbar assembly 50 can reduce the number of solder joints, thereby reducing the parasitic inductance of the capacitor, thereby increasing the series resonant frequency.

[0039] Specifically, Figure 7 As shown, the motor controller 100 also includes an insulating seat 25, and multiple filter X capacitor cores 21, multiple filter Y capacitor cores 22, first bus capacitor cores 23 and multiple second bus capacitor cores 24 of the integrated capacitor assembly 20 are all installed in the insulating seat 25. The insulating seat 25 is made of plastic material, which can enable each capacitor core in the integrated capacitor assembly 20 to be stably installed therein, and has an insulating effect to prevent the capacitor core from directly contacting the housing 10 and generating an electrical connection; there is also an insulating paper 26 between the capacitor cores or around the capacitor cores, which can prevent the capacitor cores from contacting each other or the capacitor cores from contacting external parts and generating an electrical connection.

[0040] Specifically, Figure 4 and Figure 7 As shown, each filter Y capacitor core 22 is provided with a grounding terminal 221 and a grounding screw 222 . The grounding screw 222 is installed on the mounting hole of the grounding terminal 221 to ground the entire integrated capacitor assembly 20 .

[0041] In another embodiment of the motor controller of the present application, a connecting harness is provided inside the circuit board 60, the circuit board 60 is covered on the integrated capacitor assembly 20, and multiple filter X capacitor cores 21, multiple filter Y capacitor cores 22, a first bus capacitor core 23, multiple second bus capacitor cores 24 and the filter inductor 30 are connected through the connecting harness inside the circuit board 60.

[0042] In a specific implementation, a large number of connecting harnesses are integrated inside the circuit board 60, which can reduce the space occupied by the connecting harnesses in the housing 10 while ensuring stable connection between the capacitor cores, thereby reducing the space occupied by the motor controller as a whole.

[0043] like Figures 1 to 9 As shown, the motor controller of the embodiment of the present application, wherein the connecting copper bar assembly 50 includes an input copper bar 51, a negative bus copper bar 52, a positive bus copper bar 53 and an output copper bar 54, the input copper bar 51 is used to pass an external input signal, the filter inductor 30 is electrically connected to the negative bus copper bar 52 through the input copper bar 51, the negative bus copper bar 52 is covered on the negative electrode of the integrated capacitor assembly 20 and is electrically connected to the negative electrode of the integrated capacitor assembly 20 to form the negative electrode of the integrated capacitor assembly 20 as a whole, so that the input end of the power component 40 is connected to the negative electrode of the integrated capacitor assembly 20 more conveniently, the positive bus copper bar 53 is covered on the integrated capacitor assembly The positive electrode of the component 20 is electrically connected to the positive electrode of the integrated capacitor component 20 to form the positive electrode of the integrated capacitor component 20 as a whole, making it easier to connect the input end of the power component 40 with the positive electrode of the integrated capacitor component 20, and the integrated capacitor component 20 is clamped between the negative bus copper bar 52 and the positive bus copper bar 53, and the two ends of each capacitor core are fixedly connected to the negative bus copper bar 52 and the positive bus copper bar 53 respectively, thereby improving the overall installation stability of the integrated capacitor component 20, and the output end of the power component 40 is electrically connected to the output copper bar 54, and the output copper bar 54 is electrically connected to the motor 200 to realize the driving of the motor 200.

[0044] Specifically, Figure 3 and Figure 7 As shown, the power component 40, the negative busbar copper bar 52 and the positive busbar copper bar 53 are all arranged in parallel. Such an arrangement can reduce the space occupied by the power component 40, the negative busbar copper bar 52, the positive busbar copper bar 53 and the integrated capacitor component 20; in order to connect the parallel-arranged power component 40, the negative busbar copper bar 52 and the positive busbar copper bar 53, the connecting copper bar assembly 50 also includes a positive connecting copper bar 56 and a negative connecting copper bar 57. The positive connecting copper bar 56 can connect the input end of the power component 40 with the positive busbar copper bar 53, and the negative connecting copper bar 57 can connect the input end of the power component 40 with the negative busbar copper bar 52.

[0045] like Figure 4 As shown, the motor controller of the embodiment of the present application, wherein the connection copper bar assembly 50 further includes a boost charging copper bar 55, which is electrically connected to the positive electrode of the integrated capacitor assembly 20, and the boost charging copper bar 55 has a relay connection port 551, and the relay assembly 400 of the electric drive device is electrically connected to the boost charging copper bar 55 through the relay connection port 551. The setting of the relay connection port 551 facilitates the connection between the boost charging copper bar 55 and the relay assembly 400 through the connector, thereby increasing the connection stability between the boost charging copper bar 55 and the relay assembly 400.

[0046] During specific implementation, the boost charging copper bus 55 is connected to the relay assembly 400, and the on and off of the relay assembly 400 is controlled by a control voltage signal, thereby being able to control the on and off of the entire boost charging filter circuit. When the relay assembly 400 is in the on state, the boost charging filter circuit inside the motor controller 100 is turned on as a whole, and the motor controller 100 can boost charge the battery structure connected thereto; when the relay assembly 400 is in the off state, the boost charging filter circuit inside the motor controller 100 is disconnected, the drive circuit is turned on, and the motor controller 100 can drive the motor 200.

[0047] Specifically, the relay connection port 551 is a screw hole, which facilitates the connection between the boost charging copper busbar 55 and the relay assembly 400 through bolts, and the combination of the bolts and the screw holes facilitates the disassembly between the boost charging copper busbar 55 and the relay assembly 400, and when the relay assembly 400 is damaged, it is easy to replace.

[0048] like Figure 7 As shown, the motor controller of the embodiment of the present application, wherein the input copper bar 51 includes a positive input copper bar 511, a negative input copper bar 512 and a boost charging input copper bar 513, the positive input copper bar 511 is electrically connected to the positive bus copper bar 53, the negative input copper bar 512 is electrically connected to the negative bus copper bar 52, and the boost charging input copper bar 513 is electrically connected to the boost charging copper bar 55. The arrangement of the positive input copper bar 511, the negative input copper bar 512 and the boost charging input copper bar 513 divides the main voltage signal into three paths to form a complete drive circuit and a boost charging filter circuit, thereby realizing the functions of drive and boost charging.

[0049] Specifically, the positive input copper bar 511, the negative input copper bar 512 and the boost charging input copper bar 513 are all arranged in the filter inductor 30, so that the filter inductor 30 can be arranged in a three-way circuit, and a boost charging circuit can be formed between the part of the filter inductor 30 connected to the positive input copper bar 511 and the negative input copper bar 512 and the multiple filter X capacitor cores 21 and the first bus capacitor core 23, and a filter circuit can be formed between the part of the filter inductor 30 connected to the boost charging input copper bar 513 and the multiple filter Y capacitor cores 22 and the multiple second bus capacitor cores 24, thereby forming a complete boost charging filter circuit.

[0050] like Figure 8 and Fig. 9 As shown, a motor controller of an embodiment of the present application, wherein the positive busbar copper busbar 53 has a protruding positive connection terminal 531, the negative busbar copper busbar 52 has a protruding negative connection terminal 521, the boost charging copper busbar 55 has a protruding boost charging connection terminal 552, and the positive connection terminal 531, the negative connection terminal 521 and the boost charging connection terminal 552 are all extended toward the direction of the input copper busbar 51 and are electrically connected to the input copper busbar 51.

[0051] In a specific implementation, the protruding positive connection terminal 531, the negative connection terminal 521 and the boost charging connection terminal 552 are all extended toward the direction of the input copper busbar 51, which can facilitate the connection of the positive input copper busbar 511, the negative input copper busbar 512 and the boost charging input copper busbar 513 of the input copper busbar 51, and such an arrangement can arrange the positive connection terminal 531, the negative connection terminal 521 and the boost charging connection terminal 552 in the same area, thereby reducing the occupied space, and further reducing the space occupied by the boost charging device as a whole.

[0052] Specifically, the positive electrode connection terminal 531 , the negative electrode connection terminal 521 , and the boost charging connection terminal 552 are connected to the input copper bus 51 by welding. The welding connection method can improve the connection strength, thereby ensuring the stability of the internal circuit.

[0053] like Figure 3 As shown, the motor controller of an embodiment of the present application, wherein the power component 40 includes three half-bridge power modules, the output copper bus 54 includes three copper buses for outputting three-phase electricity, and the three half-bridge power modules are connected to the three copper buses of the output copper bus 54 in a one-to-one correspondence.

[0054] In specific implementation, the three half-bridge power modules can convert the DC voltage signal into an AC voltage signal and output it to the output copper bus 54 to drive the motor 200. Under the driving action of the three-phase AC power, the motor 200 can work normally.

[0055] Specifically, the three half-bridge power modules are connected to the output copper bus 54 by laser welding, which can improve the connection strength and ensure the connection stability.

[0056] Specifically, the circuit board 60 has a driving module and a control module connected to the power component 40. The driving module is connected to the pin terminals of the power component 40 and is used to drive the power component 40. The motor controller 100 also includes a shielding cover 61, which is arranged under the control module part of the circuit board 60 and is used to shield the electromagnetic signal of the power component 40 to avoid electromagnetic interference to the control module.

[0057] like Figure 3 As shown, the motor controller of the embodiment of the present application, wherein the motor controller 100 also includes a water cooling plate 70, which is installed between the integrated capacitor component 20 and the power component 40 for cooling the integrated capacitor component 20 and the power component 40.

[0058] In a specific implementation, the integrated capacitor component 20 and the power component 40 are relatively large in size and generate relatively high heat during operation. A water cooling plate 70 is provided between the integrated capacitor component 20 and the power component 40 to enable timely cooling, thereby ensuring the overall operation effect of the motor controller 100.

[0059] Specifically, the shell 10 has a water pipe joint 11, which is connected to the water cooling plate 70. Cooling water can enter the water cooling plate 70 through the water pipe joint 11. When the cooling water needs to be replaced, the cooling water in the water cooling plate 70 flows out through the water pipe joint 11 to realize the circulation of cooling water, so as to ensure the cooling effect of the water cooling plate 70 on the motor controller 100.

[0060] Optionally, two water pipe joints 11 can be provided, one for introducing cooling water into the water cooling plate 70 , and the other for discharging the cooling water in the water cooling plate 70 , to ensure that the cooling water in the water cooling plate 70 always maintains a low temperature, thereby achieving a real-time cooling effect of the water cooling plate 70 .

[0061] like Figure 5 As shown, the motor controller of the embodiment of the present application, wherein the motor controller 100 further includes a fixed insulating layer 80, the fixed insulating layer 80 is encapsulated between the integrated capacitor assembly 20 and the water-cooled plate 70, and is used to fix the integrated capacitor assembly 20, the filter inductor 30 and the connecting copper bar assembly 50. The fixed insulating layer 80 can fix and encapsulate the integrated capacitor assembly 20 composed of multiple capacitor cores, the separately arranged filter inductor 30 and part of the connecting copper bar assembly 50 in the housing 10, thereby improving the installation stability of the internal parts of the motor controller 100, and avoiding the internal parts of the motor controller 100 from shaking and falling when the vehicle is running and generating violent movements.

[0062] Specifically, the fixed insulating layer 80 is epoxy resin, and through the potting process, the liquid epoxy resin can be solidified into the fixed insulating layer 80 adapted to the internal shape of the housing 10, so as to be fixed inside the housing 10, and the integrated capacitor assembly 20, the filter inductor 30 and the connecting copper busbar assembly 50 are fixed. The potting process and the material selection of epoxy resin avoid the process of designing the fixed insulating layer 80 according to the internal shape of the housing 10, reduce the production and assembly time, and improve the production efficiency.

[0063] Specifically, the negative busbar copper bar 52 also includes a negative electrode welding portion 522, and the positive busbar copper bar 53 also includes a positive electrode welding portion 532. The negative electrode welding portion 522 and the positive electrode welding portion 532 both extend toward the fixed insulating layer 80 and protrude from the fixed insulating layer 80, so that the positive electrode connection copper bar 56 can be welded and connected to the positive electrode welding portion 532, and the negative electrode connection copper bar 57 can be welded and connected to the negative electrode welding portion 522, so that the power component 40 can be connected to the integrated capacitor component 20 under the isolation of the fixed insulating layer 80.

[0064] like Figure 3 and Figure 5 As shown, the motor controller of the embodiment of the present application, wherein the motor controller 100 also includes a high-voltage connector terminal 90, an adapter component 91 and a signal connector terminal 92, the output end of the high-voltage connector terminal 90 is electrically connected to the input copper bus 51 through the adapter component 91, and the input end of the high-voltage connector terminal 90 is used to receive an external high-voltage signal; the output end of the signal connector terminal 92 is electrically connected to the relay component 400 of the electric drive device, and the input end of the signal connector terminal 92 is used to receive an external control signal, and the control signal can turn on or off the relay component 400.

[0065] Specifically, the housing 10 also has a high-voltage input port 12 and a signal input port 13. The high-voltage input port 12 is connected to the high-voltage connector terminal 90 for inputting an external main voltage signal, and the signal input port 13 is connected to the signal connector terminal 92 for inputting an external control voltage signal. Both the high-voltage input port 12 and the high-voltage connector terminal 90 are integrated 3-pin connectors, which realize the integration effect of 3 input circuits, reduce the setting of ports and terminals, thereby reducing the number of related fasteners and auxiliary parts between the ports and terminals, simplifying the assembly process, and reducing cost and weight.

[0066] Specifically, the adapter assembly 91 includes three adapter copper plates, which are respectively welded to the positive input copper bus 511, the negative input copper bus 512 and the boost charging input copper bus 513, thereby realizing the connection between the high-voltage connector terminal 90 and the input copper bus 51 and ensuring the connection stability.

[0067] like Figure 1As shown, an embodiment of the present application also provides an electric drive device, wherein the electric drive device includes the above-mentioned motor controller, and the electric drive device also includes a motor 200, a reducer 300 and a relay assembly 400 connected to each other, the relay assembly 400 includes a relay connecting copper bus 410 and a relay 420, the relay 420 is electrically connected to the motor controller 100 via the relay connecting copper bus 410, and the relay is also electrically connected to the motor 200 and the reducer 300 to form a boost charging filter circuit and a drive circuit.

[0068] Specifically, the relay 420 also has a connecting harness, which is electrically connected to the signal connector terminal 92 to achieve the control of the on-off of the relay 420 by the control voltage signal, thereby achieving the switching between the boost charging filter circuit and the drive circuit.

[0069] Specifically, the relay connection copper busbar 410 is connected to the relay 420 via two connection screws, and the two connection screws are also respectively connected to the relay connection port 551 and the neutral point interface of the motor 200 to form a complete loop.

[0070] An embodiment of the present application also provides a vehicle, wherein the vehicle includes the above-mentioned electric drive device.

[0071] The vehicle of the embodiment of the present application includes an electric drive device, and the electric drive device includes a motor controller 100. The motor controller 100 includes a housing 10, an integrated capacitor assembly 20, a filter inductor 30, a power assembly 40, a connecting copper bar assembly 50 and a circuit board 60. The integrated capacitor assembly 20, the filter inductor 30, the power assembly 40, the connecting copper bar assembly 50 and the circuit board 60 are all arranged inside the housing 10, and the integrated capacitor assembly 20, the filter inductor 30 and the power assembly 40 are electrically connected by connecting the copper bar assembly 50 and the circuit board 60 to form a boost charging filter circuit and a drive circuit. The boost charging filter circuit can realize the boost charging function of the battery structure, and the drive circuit can drive the motor 200 to work. Relative to the independently arranged boost charging device, the motor controller in the present application integrates the components required for the boost charging filter circuit constituting the drive circuit and the boost charging device into a housing 10, which is equivalent to integrating the boost charging device into the motor controller used only for driving the motor 200, reducing the space occupied by the boost charging device, thereby reducing the manufacturing cost of the whole vehicle.

[0072] It should be noted that, in this article, relational terms such as "first" and "second" are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the term "comprises" or any other variant thereof is intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence "comprise a ..." do not exclude the existence of other identical elements in the process, method, article or device including the elements.

Claims

1. A motor controller, characterized in that: The motor controller (100) is used to pass an external input signal into a battery structure and a motor (200) of an electric drive device. The motor controller (100) comprises a housing (10), an integrated capacitor assembly (20), a filter inductor (30), a power assembly (40), a connecting copper bus assembly (50) and a circuit board (60). The integrated capacitor assembly (20), the filter inductor (30) and the power assembly (40) are electrically connected via the connecting copper bus assembly (50) and the circuit board (60) to form a boost charging filter circuit and a drive circuit. The integrated capacitor assembly (20), the filter inductor (30), the power assembly (40), the connecting copper bus assembly (50) and the circuit board (60) are all arranged in the housing (10).

2. The motor controller according to claim 1, characterized in that: The integrated capacitor assembly (20) comprises a plurality of filter X capacitor cores (21), a plurality of filter Y capacitor cores (22), a first bus capacitor core (23) and a plurality of second bus capacitor cores (24); the plurality of filter X capacitor cores (21), the first bus capacitor core (23) and the filter inductor (30) are electrically connected via the connecting copper busbar assembly (50) and the circuit board (60) to form a boost charging circuit; The plurality of filtering Y capacitor cores (22), the plurality of the second bus capacitor cores (24) and the filtering inductor (30) are electrically connected via the connecting copper busbar assembly (50) and the circuit board (60) to form a filtering circuit.

3. The motor controller according to claim 2, characterized in that: A connecting harness is provided inside the circuit board (60), and the circuit board (60) is covered on the integrated capacitor assembly (20); a plurality of the filter X capacitor cores (21), a plurality of the filter Y capacitor cores (22), the first bus capacitor cores (23), a plurality of the second bus capacitor cores (24), and the filter inductor (30) are connected via the connecting harness inside the circuit board (60).

4. The motor controller according to claim 1, characterized in that: The connecting copper bar assembly (50) comprises an input copper bar (51), a negative bus copper bar (52), a positive bus copper bar (53) and an output copper bar (54); the input copper bar (51) is used to input the external input signal; the filter inductor (30) is electrically connected to the negative bus copper bar (52) via the input copper bar (51); the negative bus copper bar (52) is covered on the negative electrode of the integrated capacitor assembly (20) and is connected to the integrated capacitor assembly ( The positive bus copper bar (53) is covered on the positive electrode of the integrated capacitor assembly (20) and is electrically connected to the positive electrode of the integrated capacitor assembly (20); the input end of the power assembly (40) is electrically connected to the positive bus copper bar (53) and the negative bus copper bar (52); the output end of the power assembly (40) is electrically connected to the output copper bar (54); and the output copper bar (54) is electrically connected to the motor (200).

5. The motor controller according to claim 4, characterized in that: The connecting copper busbar assembly (50) further comprises a boost charging copper busbar (55) electrically connected to the positive electrode of the integrated capacitor assembly (20); the boost charging copper busbar (55) has a relay connection port (551); and the relay assembly (400) of the electric drive device is electrically connected to the boost charging copper busbar (55) via the relay connection port (551).

6. The motor controller according to claim 5, characterized in that: The input copper bar (51) comprises a positive input copper bar (511), a negative input copper bar (512) and a boost charging input copper bar (513); the positive input copper bar (511) is electrically connected to the positive bus copper bar (53); the negative input copper bar (512) is electrically connected to the negative bus copper bar (52); and the boost charging input copper bar (513) is electrically connected to the boost charging copper bar (55).

7. The motor controller according to claim 6, characterized in that: The positive busbar copper bar (53) has a protruding positive connection end (531), the negative busbar copper bar (52) has a protruding negative connection end (521), and the boost charging copper bar (55) has a protruding boost charging connection end (552). The positive connection end (531), the negative connection end (521) and the boost charging connection end (552) are all extended in the direction of the input copper bar (51) and are electrically connected to the input copper bar (51).

8. The motor controller according to claim 4, characterized in that: The power assembly (40) comprises three half-bridge power modules (41), the output copper busbar (54) comprises three copper busbars for outputting three-phase electricity, and the three half-bridge power modules (41) are connected to the three copper busbars of the output copper busbar (54) in a one-to-one correspondence.

9. The motor controller according to claim 1, characterized in that: The motor controller (100) further comprises a water cooling plate (70), wherein the water cooling plate (70) is installed between the integrated capacitor component (20) and the power component (40) and is used for cooling the integrated capacitor component (20) and the power component (40).

10. The motor controller according to claim 9, characterized in that: The motor controller (100) further comprises a fixed insulating layer (80), wherein the fixed insulating layer (80) is embedded between the integrated capacitor assembly (20) and the water cooling plate (70) and is used to fix the integrated capacitor assembly (20), the filter inductor (30) and the connecting copper busbar assembly (50).

11. The motor controller according to claim 4, characterized in that: The motor controller (100) further comprises a high-voltage connector terminal (90), a switching assembly (91) and a signal connector terminal (92); the output end of the high-voltage connector terminal (90) is electrically connected to the input copper bus (51) through the switching assembly (91); and the input end of the high-voltage connector terminal (90) is used to receive an external high-voltage signal; The output end of the signal connector terminal (92) is electrically connected to the relay component (400) of the electric drive device, and the input end of the signal connector terminal (92) is used to receive an external control signal, and the control signal can turn on or off the relay component (400).

12. An electric drive device, characterized in that: The electric drive device comprises a motor controller as claimed in any one of claims 1 to 11, and further comprises a motor (200), a reducer (300) and a relay assembly (400) connected thereto, wherein the relay assembly (400) comprises a relay connection busbar (410) and a relay (420), wherein the relay (420) is electrically connected to the motor controller (100) via the relay connection busbar (410), and the relay is also electrically connected to the motor (200) and the reducer (300) to form a boost charging filter circuit and a drive circuit.

13. A vehicle, characterized in that: The vehicle includes the electric drive device according to claim 12.

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