Motor controller and vehicle

Abstract

The invention discloses a motor controller and a vehicle, the motor controller comprises a shell, a high-voltage filter, a support capacitor and a power module, the shell is internally provided with an accommodating space, and the high-voltage filter, the support capacitor and the power module are horizontally arranged in the accommodating space; the high-voltage filter comprises input terminals which are arranged at intervals, the input terminals are electrically connected with the filter capacitor, and the end parts of the input terminals are exposed; heat dissipation bosses distributed at intervals are arranged on the inner wall of the shell, the exposed input terminals correspond to the heat dissipation bosses, and the input terminals are located above the heat dissipation bosses; the bottom wall of the shell is provided with a cooling flow channel containing cooling liquid, and the cooling flow channel is located below the high-voltage filter, the supporting capacitor and / or the power module; the orthographic projection of the power module, the supporting capacitor and / or the high-voltage filter and the orthographic projection of the cooling flow channel are at least partially overlapped in the direction that the input terminal points to one side of the heat dissipation boss. The heat dissipation effect of the high-voltage filter is effectively improved, so that the reliability of the high-voltage filter is improved.

Description

Technical Field

[0001] The present invention relates to the field of vehicle technology, and more particularly, to a motor controller and a vehicle. Background Art

[0002] With the increasing attention paid to environmental protection around the world, the development of new energy vehicles is getting faster and faster. Among them, extended-range new energy vehicles have been favored by consumers due to their advantages such as long driving range and convenient charging. In the power-deficient mode, the range extender of the extended-range new energy vehicle will start to generate electricity. When the range extender is running, a large amount of heat will be generated. This heat will be transferred to the motor controller connected to it, causing the ambient temperature of the motor controller to rise, making it difficult for the motor controller to dissipate heat. At the same time, the power module, support capacitor, and high-voltage filter inside the motor controller will generate a lot of heat when running, causing the temperature of the motor controller to rise.

[0003] The prior art uses coolant to dissipate heat from the power module and supporting capacitors. The only way to dissipate heat from the high-voltage filter is through the contact between the mounting base on its housing and the housing of the motor controller. The contact area between the two is small, and heat is not dissipated from the heat source of the high-voltage filter (such as the positive copper busbar and the negative copper busbar). This results in extremely poor heat dissipation effect, causing the overall temperature of the high-voltage filter to rise rapidly.

[0004] In the prior art, the maximum allowable operating temperature of the filter capacitor on the high-voltage filter is 110°C. If the motor controller of the extended-range new energy vehicle adopts the above solution, the operating temperature of the filter capacitor of the high-voltage filter can easily exceed 110°C, or even reach above 120°C, which reduces the life of the filter capacitor of the high-voltage filter or even makes it fail, resulting in poor filtering performance of the high-voltage filter and threatening the reliability of vehicle driving. Therefore, how to effectively solve the heat dissipation problem of the high-voltage filter and reduce the operating temperature of its filter capacitor is a technical problem that needs to be solved in this field. Summary of the invention

[0005] In view of this, the present invention provides a motor controller to solve the problem that the operating temperature of the filter capacitor on the high-voltage filter easily exceeds its maximum operating temperature, which reduces the life of the filter or even causes it to fail.

[0006] In a first aspect, the present application provides a motor controller, including a housing, a high-voltage filter, a support capacitor and a power module, wherein:

[0007] The housing has a containing space inside, and the high-voltage filter, the supporting capacitor and the power module are horizontally arranged in the containing space;

[0008] The high-voltage filter comprises input terminals arranged at intervals, the input terminals are electrically connected to the filter capacitor, and the ends of the input terminals are exposed;

[0009] The housing has an inner wall provided with heat dissipation bosses distributed at intervals, the exposed input terminals correspond to the heat dissipation bosses, and the input terminals are located above the heat dissipation bosses;

[0010] The housing has a bottom wall provided with a cooling channel containing a coolant, and the cooling channel is located below the high-voltage filter, the supporting capacitor and / or the power module;

[0011] Along the direction from the input terminal to one side of the heat dissipation boss, the orthographic projection of the power module, the supporting capacitor and / or the high-voltage filter at least partially overlaps with the orthographic projection of the cooling channel.

[0012] In a second aspect, the present application provides a vehicle comprising the above-mentioned motor controller.

[0013] Compared with the prior art, the motor controller and vehicle provided by the present invention achieve at least the following beneficial effects:

[0014] The motor controller and vehicle provided by the present invention, the motor controller, by contacting the exposed first input terminal and the second input terminal with the heat dissipation boss, is conducive to heat dissipation from the heat generation source of the high-voltage filter, effectively improving the heat dissipation effect of the high-voltage filter, thereby improving its reliability; through a cooling flow channel containing coolant, and designing the high-voltage filter, the power module and / or the support capacitor above the cooling flow channel, it is more conducive to reducing the temperature on the filter capacitor, effectively preventing the filter capacitor from reducing its service life due to exceeding its operating temperature, and improving the reliability of the high-voltage filter; at the same time, since the power module, the support capacitor and the high-voltage filter are arranged in a flat manner, the dimension along the depth of the accommodating space can also be greatly reduced, which is convenient for subsequent maintenance and disassembly, and at the same time can increase the heat dissipation area, thereby further improving the heat dissipation effect of the high-voltage filter.

[0015] Of course, any product implementing the present invention does not necessarily need to achieve all of the technical effects described above at the same time.

[0016] Further features and advantages of the present invention will become apparent from the following detailed description of exemplary embodiments of the present invention with reference to the attached drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

[0018] Figure 1 is a top view of a motor controller provided by the present invention;

[0019] Figure 2yes Figure 1 Schematic diagram of the structure of A-A';

[0020] Figure 3 is a top view of another motor controller provided by the present invention;

[0021] Figure 4 It is a structural schematic diagram of a part of cooling water channel provided by the present invention;

[0022] Figure 5 is a top view of another motor controller provided by the present invention;

[0023] Figure 6 yes Figure 5 Schematic diagram of the structure of B-B';

[0024] Figure 7 It is a top view of another motor controller provided by the present invention. DETAILED DESCRIPTION

[0025] Various exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It should be noted that the relative arrangement of components and steps, numerical expressions and numerical values ​​set forth in these embodiments do not limit the scope of the present invention unless otherwise specifically stated.

[0026] The following description of at least one exemplary embodiment is merely illustrative in nature and is in no way intended to limit the invention, its application, or uses.

[0027] Technologies, methods, and equipment known to ordinary technicians in the relevant art may not be discussed in detail, but where appropriate, the technologies, methods, and equipment should be considered part of the specification.

[0028] In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not limiting. Therefore, other examples of the exemplary embodiments may have different values.

[0029] It should be noted that like reference numerals and letters refer to similar items in the following figures, and therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0030] Embodiment 1

[0031] Reference Figure 1-Figure 3 As shown, Figure 1 is a top view of a motor controller provided by the present invention; Figure 2 yes Figure 1 Schematic diagram of the structure of A-A'; Figure 3is a top view of another motor controller provided by the present invention; a motor controller in this embodiment includes a housing 1, a high-voltage filter 2, a support capacitor 3 and a power module 4, wherein:

[0032] The housing 1 has a receiving space 10 therein, the high-voltage filter 2, the supporting capacitor 3 and the power module 4 are placed in the receiving space 10, and the high-voltage filter 2, the supporting capacitor 3 and the power module 4 are horizontally arranged in the receiving space 10; the high-voltage filter 2 includes input terminals 22 arranged at intervals, the input terminals 22 are electrically connected to the filter capacitor 20, and the ends of the input terminals 22 are exposed;

[0033] The housing 1 has heat dissipation bosses 11 arranged at intervals on its inner wall, and the exposed input terminals 22 correspond to the heat dissipation bosses 11, and the input terminals 22 are located above the heat dissipation bosses 11;

[0034] The housing 1 has a bottom wall provided with a cooling channel 5 containing a coolant, and the cooling channel 5 is located below the high-voltage filter 2, the supporting capacitor 3 and the power module 4;

[0035] Along the direction Z where the input terminal 22 points to one side of the heat dissipation boss 11 , the orthographic projection of the power module 4 , the supporting capacitor 3 and / or the high-voltage filter 2 overlaps with the orthographic projection of the cooling channel 5 .

[0036] Specifically, continue to refer to Figure 1 As shown, the motor controller includes a housing 1, and a housing 1 has a housing space 10 therein. The housing space 10 may be a rectangular housing space. On opposite surfaces of the housing 1, a high-voltage filter 2, a supporting capacitor 3, and a power module 4 are horizontally arranged in the housing space 10.

[0037] The high-voltage filter 2 includes input terminals 22 arranged at intervals, such as the input terminal 22 including a first input terminal 221 and a second input terminal 222, with a gap between the first input terminal 221 and the second input terminal 222, the first input terminal 221 and the second input terminal 222 can pass through the filter magnetic ring 21 to be electrically connected to the filter capacitor 20 respectively, the ends of the first input terminal 221 and the second input terminal 222 are both exposed, if the first input terminal 221 and the second input terminal 222 of the heat dissipation part need to be exposed from the housing of the high-voltage filter 2, and can subsequently contact the heat dissipation boss 11 through the insulating layer, which is conducive to the heat dissipation of the first input terminal 221 and the second input terminal 222, thereby dissipating the heat at the source of the heat generated by the high-voltage filter 2, effectively improving the heat dissipation effect, and then improving the reliability of the high-voltage filter. The material of the housing of the high-voltage filter 2 can be insulating resin, which can be formed by injection molding.

[0038] In this embodiment, when the input terminal 22 includes the first input terminal 221 and the second input terminal 222, the polarities of the first input terminal 221 and the second input terminal 222 are different, such as the first input terminal 221 can be a positive copper busbar, and the second input terminal 222 can be a negative copper busbar; of course, according to actual conditions, the first input terminal 221 can also be a negative copper busbar, and the second input terminal 222 can be a positive copper busbar, which is not specifically limited in this embodiment.

[0039] The shell 1 has an inner wall provided with heat dissipation bosses 11 distributed at intervals, and there are gaps between different heat dissipation bosses 11. When the input terminal 22 includes a first input terminal 221 and a second input terminal 222, the first input terminal 221 and the second input terminal 222 are exposed to correspond to different heat dissipation bosses 11 respectively. It can be understood that the first input terminal 221 and the second input terminal 222 are respectively located above different heat dissipation bosses 11. The bottom wall of the shell 1 is provided with a cooling channel 5 containing coolant, and the cooling channel 5 can be located below the power module 4, the supporting capacitor 3 and the high-voltage filter 2.

[0040] It should be noted that in order to avoid a short circuit, an insulating layer may be provided between the input terminal 22 and the heat dissipation boss 11 , and the insulating layer may be a heat conductive layer.

[0041] Continuing with reference to 2 , the heat dissipation boss 11 extends in the direction of the input terminal 22 pointing to the side of the thermal conductive layer 6. For example, the heat dissipation boss 11 can be a cubic boss and a cylindrical boss. The cubic boss and the cylindrical boss are two different geometric bosses. The cubic boss is a geometric body with six faces, each of which is a square; the cylindrical boss is a geometric body with two parallel circular faces, and the side faces are connected by curves to form a column.

[0042] Combination Figure 1 and Figure 2 As shown, in this embodiment, the cooling channel 5 passes under the high-voltage filter 2, and the coolant flows from the liquid inlet pipe 54 into the cooling channel under the high-voltage filter 2, and flows through the cooling channel 5 under the supporting capacitor and the cooling channel under the power module 4 in sequence, and gradually cools the high-voltage filter 2, the supporting capacitor 3 and the power module 4. In addition, since the cooling channel 5 is located below the high-voltage filter 2, the supporting capacitor 3 and the power module 4, the cooling channel 5 is separated from the accommodating space 10, thereby effectively preventing the leakage of the coolant from affecting the normal operation of the high-voltage filter 2, the supporting capacitor 3 and the power module 4.

[0043] A part of the heat generated by the first input terminal 221 and the second input terminal 222 under large current is dissipated into the air through heat dissipation, and most of it is transferred to the heat dissipation boss 11 through the heat conductive layer 6, and then transferred to the housing 1 by the heat dissipation boss 11, that is, a small part of the heat on the housing 1 is dissipated into the air through heat dissipation, and most of the heat is taken away by the coolant through thermal convection between the housing 1 and the coolant. Since the first input terminal 221 and the second input terminal 222 are the heat generation sources of the high-voltage filter 2, the heat is dissipated at the heat generation sources of the high-voltage filter 2, which can more effectively improve its heat dissipation effect, thereby improving the reliability of the high-voltage filter.

[0044] The above phenomenon can be explained by Newton's cooling formula, which describes the heat exchange process between an object and its surrounding environment. In the high-voltage filter 2, the input terminal 22 acts as a heating element, and there is convection heat exchange and radiation heat exchange between its surface and the air. Convection heat transfer refers to the transfer of heat from the surface of the input terminal 22 to the air through air flow, while thermal radiation refers to the transfer of heat by the surface of the input terminal 22 directly emitting electromagnetic waves into space. These two methods work together to dissipate part of the heat generated by the input terminal 22 under high current into the air, thereby keeping the temperature of the input terminal 22 within a relatively safe range.

[0045] Both heat radiation and heat convection are effective in dissipating the heat generated by the input terminal 22 under high current into the air, thereby maintaining stable operation of the system and preventing damage or performance degradation of the high-voltage filter 2 due to overheating.

[0046] Compared with the prior art, the motor controller provided in this embodiment achieves at least the following beneficial effects:

[0047] The motor controller provided in this embodiment, by contacting the exposed first input terminal and the second input terminal with the heat dissipation boss, is conducive to heat dissipation from the heat generation source of the high-voltage filter, effectively improving the heat dissipation effect of the high-voltage filter, thereby improving its reliability; through a cooling flow channel containing coolant, and designing the high-voltage filter, the power module and / or the support capacitor above the cooling flow channel, it is more conducive to reducing the temperature on the filter capacitor, effectively preventing the filter capacitor from reducing its service life due to exceeding its operating temperature, and improving the reliability of the high-voltage filter; at the same time, since the power module, the support capacitor and the high-voltage filter are arranged in a flat manner, the dimension along the depth of the accommodating space can also be greatly reduced, which is convenient for subsequent maintenance and disassembly, and at the same time can increase the heat dissipation area, thereby further improving the heat dissipation effect of the high-voltage filter.

[0048] In some optional embodiments, continue to refer to Figure 2As shown, the cooling channel 5 includes a filter cooling sub-channel 51, a capacitor cooling sub-channel 52 and a power cooling sub-channel 53 which are connected to each other; along the direction Z pointing from the input terminal 22 to one side of the heat dissipation boss 11, the orthographic projection of the filter cooling sub-channel 51 overlaps with the orthographic projection of the high-voltage filter 2, the orthographic projection of the capacitor cooling sub-channel 52 overlaps with the orthographic projection of the supporting capacitor 3, and the orthographic projection of the power cooling sub-channel 53 overlaps with the orthographic projection of the power module 4.

[0049] Specifically, the cooling channel 5 includes a filter cooling sub-channel 51, a capacitor cooling sub-channel 52 and a power cooling sub-channel 53, wherein the filter cooling sub-channel 51 is located below the high-voltage filter 2, the capacitor cooling sub-channel 52 is located below the supporting capacitor 3, and the power cooling sub-channel 53 is located below the power module 4. The filter cooling sub-channel 51 and the power cooling sub-channel 53 are respectively connected to the capacitor cooling sub-channel 52, which is beneficial for the coolant to enter from the liquid inlet pipe 54 and take away the heat generated by the high-voltage filter 2, the supporting capacitor 3 and the power module 4 in turn, thereby facilitating the heat dissipation of the motor controller.

[0050] Optionally, combined Figure 1 and Figure 2 As shown, the cooling channel 5 includes a liquid inlet pipe 54 and a liquid outlet pipe 55 which are connected. The liquid inlet pipe 54 is located on the side of the filter cooling sub-channel 51 away from the capacitor cooling sub-channel 52, and the liquid outlet pipe 55 is located on the side of the power cooling sub-channel 53 away from the capacitor cooling sub-channel 52. Since the liquid inlet pipe 54 is close to the side of the high-voltage filter 2, the coolant can first pass through the bottom of the high-voltage filter 2, which greatly improves the heat dissipation effect of the high-voltage filter 2. For example, the temperature of the filter capacitor 20 of the high-voltage filter 2 is reduced to below 105°C, which can prevent the filter capacitor 20 of the high-voltage filter 2 from being damaged due to exceeding the operating temperature, that is, effectively improve the service life of the filter capacitor 20, thereby ensuring the operation of the high-voltage filter 2.

[0051] It should be noted that: the extension direction of the liquid inlet pipe 54 can be the direction from the high-voltage filter 2 to the side of the power module 4, and the extension direction of the liquid inlet pipe 54 intersects with the extension direction of the liquid outlet pipe 55. For example, the opening of the liquid inlet pipe 54 is toward the right side of the shell 1, and the opening of the liquid outlet pipe 55 is toward the rear side of the shell 1. Since the liquid inlet pipe 54 is close to the high-voltage filter 2, it is more conducive to the heat dissipation of the high-voltage filter 2.

[0052] Optionally, continue to refer to Figure 3As shown, the cooling channel 5 includes a liquid inlet pipe 54 and a liquid outlet pipe 55 which are connected. The liquid inlet pipe 54 is located on the side of the power cooling sub-channel 53 away from the capacitor cooling sub-channel 52, and the liquid outlet pipe 55 is located on the side of the filter cooling sub-channel 51 away from the capacitor cooling sub-channel 52. In this scheme, the coolant first passes through the bottom of the power module 4, which can greatly improve the heat dissipation effect of the power module 4. Since the local temperature in the shell 1 is reduced, the heat generated by the subsequent high-voltage filter 2 is transferred to the low temperature. At the same time, the coolant can also pass through the bottom of the high-voltage filter 2. If the liquid outlet pipe 55 is close to the side of the high-voltage filter 2, the heat dissipation effect of the high-voltage filter 2 can also be improved, thereby preventing the filter capacitor 20 of the high-voltage filter 2 from being damaged due to exceeding the operating temperature.

[0053] It should be noted that: continue to refer to Figure 3 As shown, the extension direction of the liquid outlet pipe 55 can be the direction from the high-voltage filter 2 to the side of the power module 4, and the extension direction of the liquid inlet pipe 54 intersects with the extension direction of the liquid outlet pipe 55. For example, the opening of the liquid outlet pipe 55 is toward the right side of the shell 1, and the opening of the liquid inlet pipe 54 is toward the rear side of the shell 1. Since the liquid outlet pipe 55 is close to the high-voltage filter 2, the coolant can also pass through the bottom of the high-voltage filter 2, which is beneficial to the heat dissipation of the high-voltage filter 2.

[0054] Optionally, the diameter of the liquid inlet pipe 54 is the same as the diameter of the liquid outlet pipe 55, so as to ensure that the flow rate of the coolant is consistent, so that the heat dissipation of the high-voltage filter 2, the support capacitor 3 and the power module 4 is more uniform.

[0055] See also Figure 4 As shown, Figure 4 It is a schematic diagram of the structure of a partial cooling water channel provided by the present invention; according to the structural design of the supporting capacitor 3, the capacitor cooling sub-channel 52 can be designed as follows:

[0056] The capacitor cooling sub-channel 52 includes a plurality of U-shaped pipes 520 arranged at intervals, and the plurality of U-shaped pipes 520 are connected to each other through a straight pipe 521. The U-shaped pipe 520 close to the filter cooling sub-channel 51 is connected to the filter cooling sub-channel 51, and the U-shaped pipe 520 close to the power cooling sub-channel 53 is connected to the power cooling sub-channel 53, so that the cooling liquid can flow more comprehensively under the support capacitor 3, thereby comprehensively cooling the support capacitor 3. In addition, the above structure can also speed up the flow of the coolant.

[0057] In some optional embodiments, continue to refer to Figure 2As shown, the shell 1 includes a first part 12 and a second part 13 connected to the first part 12, the second part 13 is located below the first part 12, the accommodating space 10 is located in the first part 12, the cooling channel 5 is located in the second part 13, the second part 13 includes a first layer 131 and a second layer 132 connected to the first layer 131, the first layer 131 is connected to the first part 12, and a cooling channel 5 is formed between the first layer 131 and the second layer 132. It can be understood that the second part 13 of the shell 1 is a double-layer structure, the first part 12 and the second part 13 are arranged opposite to each other, and the second part 13 is located below the first part 12. The coolant flows between the first layer 131 and the second layer 132, which is beneficial to take away the heat generated by the high-voltage filter 2, the supporting capacitor 3 and the power module 4. At the same time, there is no need to set up an additional water cooling structure to save space for the motor controller and reduce costs.

[0058] Optionally, combined Figure 1 and Figure 2 As shown, the material of the housing 1 includes metal, which has high strength, good plasticity, corrosion resistance, and good heat dissipation performance. The metal includes aluminum alloy, which has a low density, only about 1 / 3 of iron, copper, and zinc, which helps to reduce the weight of the product, and has good strength, can resist impact and vibration, and has good thermal conductivity.

[0059] The material of the heat dissipation boss 11 can be the same as that of the housing 1 , which is beneficial to improving the heat dissipation effect.

[0060] Optionally, the high-voltage filter 2, the supporting capacitor 3 and the power module 4 are respectively fixed to the first part 12 by fasteners (not shown in the figure), so that the high-voltage filter 2, the supporting capacitor 3 and the power module 4 are respectively effectively fixed to the housing 1, and the overall structure is simple and easy to operate. The above-mentioned fasteners can be screws, which are a common fastener. The high-voltage filter 2, the supporting capacitor 3 and the power module 4 can be reinforced with the housing 1 by screws, thereby improving the stability and safety between the high-voltage filter 2, the supporting capacitor 3 and the power module 4 and the housing 1, and ensuring the normal use and operation of the high-voltage filter 2, the supporting capacitor 3 and the power module 4.

[0061] Optionally, along the direction X pointing from the power module 4 to the side of the high-voltage filter 2, the cross-sectional area of ​​the heat dissipation boss 11 close to the thermal conductive layer 6 is smaller than the cross-sectional area of ​​the thermal conductive layer 6 close to the heat dissipation boss 11. Since the thermal conductive layer 6 is in direct contact with the input terminal 22, the contact area between the input terminal 22 and the thermal conductive layer 6 is increased, so that the heat generated by the input terminal 22 can be quickly transferred to the heat dissipation boss 11, which is more conducive to taking away the heat generated by the input terminal 22. At the same time, it can also prevent the input terminal 22 from directly contacting the heat dissipation boss 11, so as to achieve the purpose of effective insulation.

[0062] In an optional embodiment, the coolant can be a mixed solution, and the mixed solution has a higher boiling point and a lower freezing point than water. The main components of the mixed solution include ethylene glycol, propylene glycol, diethylene glycol and silicate, etc. The mixed solution formed by mixing these mother liquors with soft water in different proportions is called antifreeze. Ethylene glycol is the basic component of antifreeze. After mixing with water, it can lower the freezing point and prevent the coolant from freezing in a low temperature environment.

[0063] The inventors found that if the temperature of the coolant is too high, the cooling effect of the components inside the shell 1 (such as the high-voltage filter 2, the support capacitor 3 and / or the power module 4) will be poor, which may easily cause the components inside the shell 1 to overheat; if the temperature of the coolant is too low, while increasing the energy consumption of the battery, the water vapor inside the shell 1 will condense due to the temperature difference, affecting the electrical performance of the motor controller.

[0064] Optionally, in this embodiment, the temperature range of the coolant can be 20°C-80°C, which can not only improve the cooling effect of the components inside the housing 1, but also reduce the energy consumption of the battery, and also prevent the condensation of water vapor inside the housing 1, thereby improving the electrical performance of the motor controller. The temperature of the coolant can be 20°C, 30°C, 40°C, 50°C, 60°C, 70°C or 80°C. Preferably, the temperature range of the coolant can be 50°C-70°C.

[0065] The inventors found that if the flow rate of the coolant is larger, the flow rate is also faster, which will affect the service life of the cooling water channel and increase the energy consumption of the battery. If the flow rate of the coolant is smaller, the cooling effect inside the shell 1 is poor, which can easily cause the components inside the shell 1 to overheat.

[0066] Optionally, in this embodiment, the flow rate of the coolant is designed to be in the range of 5L / min-15L / min, which can not only improve the cooling effect of the components inside the housing 1 and prevent the components inside the housing 1 from overheating, but also reduce the energy consumption of the battery and increase the service life of the cooling water channel. The flow rate of the coolant can be 5L / min, 6L / min, 7L / min, 8L / min, 9L / min, 10L / min, 11L / min, 12L / min, 13L / min, 14L / min or 15L / min. Preferably, the flow rate of the coolant can be in the range of 8L / min-10L / min.

[0067] Optionally, a heat-conducting layer 6 is provided between the input terminal 22 and the heat-dissipating boss 11, and the material of the heat-conducting layer 6 includes a heat-conducting insulating material, which has excellent insulation properties and good thermal conductivity. The heat-conducting insulating material has high thermal conductivity and can effectively transfer heat, thereby quickly transferring heat from a high-temperature area to a low-temperature area. The heat-conducting insulating material can be a silicone pad, which is made of silicone, and its thermal conductivity is proportional to the thermal conductivity coefficient, that is, the higher the thermal conductivity coefficient, the better the thermal conductivity of the material. At the same time, the thermal conductivity of the silicone pad is also inversely proportional to its thickness, that is, the thinner the thickness, the smaller the thermal resistance, and the better the thermal conductivity. This is because a silicone pad with a larger thickness will increase the heat transfer path, resulting in an increase in thermal resistance, thereby affecting the thermal conductivity efficiency. It should be noted that: the thickness of the silicone pad in this embodiment is not the thinner the better. If the thickness of the silicone pad is too thin, it will affect its insulation performance and there is a safety hazard of short circuit. In this embodiment, the thickness of the silicone pad after compression is in the range of 2mm-3mm, which is conducive to improving the insulation of the silicone pad. For example, the thickness of the silicone pad after compression is in the range of 2mm, 2.2mm, 2.4mm, 2.6mm, 2.8mm or 3mm. The thermal conductivity of the silicone pad in this embodiment is greater than 3W / (m·℃). The heat generated by the input terminal 22 is transferred to the heat dissipation boss 11 more quickly through the heat conductive layer 6, which is more conducive to the heat dissipation of the input terminal 22.

[0068] When the input terminal 22 includes the first input terminal 221 and the second input terminal 222, a heat conducting layer 6 is arranged between the first input terminal 221 and the second input terminal 222 and different heat dissipation bosses 11. A part of the heat generated by the first input terminal 221 and the second input terminal 222 under large current is dissipated into the air through heat dissipation, and most of it is transferred to the heat dissipation boss 11 through the heat conducting layer 6, and then transferred to the shell 1 by the heat dissipation boss 11, that is, a small part of the heat on the shell 1 is dissipated into the air through heat dissipation, and most of the heat is taken away by the coolant through thermal convection between the shell 1 and the coolant. Since the first input terminal 221 and the second input terminal 222 are the heat generation sources of the high-voltage filter 2, the heat is dissipated at the heat generation source of the high-voltage filter 2, which can more effectively improve its heat dissipation effect, thereby improving the reliability of the high-voltage filter.

[0069] Optionally, the hardness of the silicone pad may range from 45 to 55 shore 00 and have a compressibility of 10% to 20%, which can reduce the contact thermal resistance.

[0070] The hardness of the silicone pad is an important parameter when selecting materials, which directly affects the performance and use effect of the material. The thermal conductive silicone pad with a hardness of 45-55 shore 00 has good physical properties and can meet the needs. In addition, the thermal conductive silicone pad also needs to have a compressibility of 10%-20%. The thermal conductive silicone pad needs to be compressed to fill the gap between the first input terminal 221 and the second input terminal 222 and the thermal conductive layer 6, so as to achieve effective heat conduction. Appropriate compressibility can ensure that the thermal conductive silicone pad maintains stable thermal conductivity during use, and can also adapt to certain mechanical stresses and increase the durability of the material.

[0071] It should be noted that: since the hardness range of the silicone pad can be 45-55 shore 00, the hardness of the thermal conductive layer 6 is not large. The high-voltage filter 2 is fixed to the housing 1 by fasteners, which will tightly press the thermal conductive layer 6 between the first input terminal 221 and the heat dissipation boss 11, and between the second input terminal 222 and the heat dissipation boss 11, which is more conducive to the heat transfer of the high-voltage filter 2.

[0072] Optionally, along the direction X pointing from the power module 4 to the side of the high-voltage filter 2, the cross-sectional area of ​​the heat dissipation boss 11 close to the thermal conductive layer 6 is smaller than the cross-sectional area of ​​the thermal conductive layer 6 close to the heat dissipation boss 11. Since the thermal conductive layer 6 is in direct contact with the first input terminal 221 and the second input terminal 222, the contact area between the first input terminal 221 and the thermal conductive layer 6 and between the second input terminal 222 and the thermal conductive layer 6 is increased. The heat generated by the first input terminal 221 and the second input terminal 222 can be quickly transferred to the heat dissipation boss 11, which is more conducive to taking away the heat generated by the first input terminal 221 and the second input terminal 222.

[0073] Optionally, the power module 4 and the high-voltage filter 2 are electrically connected to the supporting capacitor 3 respectively. The electrical connection between the power module 4, the supporting capacitor 3 and the high-voltage filter 2 not only realizes voltage stabilization, current detection, and energy conversion, but also provides multiple protection functions, ensuring the safe and efficient operation of the extended-range electric vehicle.

[0074] It should be noted that the support capacitor 3 plays a role in smoothing the voltage inside the motor controller, mainly preventing the voltage fluctuation on the DC bus from being kept within the allowable range, and preventing the voltage overshoot and transient overvoltage from the DC bus from affecting the functional modules (such as IGBT, Insulated Gate Bipolar Transistor, insulated gate bipolar transistor). This helps to ensure the stable operation of the electric vehicle drive system and extend the service life of electronic components. The high-voltage filter 2 is used to filter out high-frequency noise and interference in the power supply to ensure the stable operation of the motor controller. At the same time, by setting appropriate protection circuits, such as overcurrent protection, overvoltage protection, etc., the motor can be prevented from being damaged by overload or abnormal voltage.

[0075] Embodiment 2

[0076] See also Figure 5-Figure 7 As shown, Figure 5 is a top view of another motor controller provided by the present invention; Figure 6 yes Figure 5 Schematic diagram of the structure of B-B'; Figure 7 is a top view of another motor controller provided by the present invention; a motor controller in this embodiment includes a housing 1, a high-voltage filter 2, a support capacitor 3 and a power module 4, wherein:

[0077] The housing 1 has a receiving space 10 therein, the high-voltage filter 2, the supporting capacitor 3 and the power module 4 are placed in the receiving space 10, and the high-voltage filter 2, the supporting capacitor 3 and the power module 4 are horizontally arranged in the receiving space 10; the high-voltage filter 2 includes input terminals 22 arranged at intervals, the input terminals 22 are electrically connected to the filter capacitor 20, and the ends of the input terminals 22 are exposed;

[0078] The housing 1 has heat dissipation bosses 11 arranged at intervals on its inner wall, and the exposed input terminals 22 correspond to the heat dissipation bosses 11, and the input terminals 22 are located above the heat dissipation bosses 11;

[0079] The housing 1 has a bottom wall provided with a cooling channel 5 containing a coolant, and the cooling channel 5 is located below the supporting capacitor 3 and the power module 4;

[0080] Along the direction Z from the input terminal 22 to the side of the heat dissipation boss 11, the orthographic projections of the power module 4 and the support capacitor 3 overlap with the orthographic projection of the cooling channel 5. It can be understood that the difference between this embodiment and the first embodiment is that along the direction Z from the input terminal 22 to the side of the heat dissipation boss 11, the orthographic projections of the power module 4 and the support capacitor 3 overlap with the orthographic projection of the cooling channel 5, while the orthographic projection of the high-voltage filter 2 does not overlap with the orthographic projection of the cooling channel 5.

[0081] Specifically, the motor controller includes a shell 1, which has a accommodating space 10. The power module 4, the supporting capacitor 3 and the high-voltage filter 2 are placed in the accommodating space 10. On the opposite side of the shell 1, the high-voltage filter 2, the supporting capacitor 3 and the power module 4 can be horizontally arranged in the accommodating space 10.

[0082] The high-voltage filter 2 includes a filter capacitor 20, and the input terminal 22 is electrically connected to the filter capacitor 20. The input terminal 22 includes a first input terminal 221 and a second input terminal 222. The polarities of the first input terminal 221 and the second input terminal 222 are different. The first input terminal 221 can be a positive copper busbar, and the second input terminal 222 can be a negative copper busbar. Of course, according to actual conditions, the first input terminal 221 can also be a negative copper busbar, and the second input terminal 222 can be a positive copper busbar. This embodiment does not make any specific limitations on this.

[0083] The housing 1 has heat dissipation bosses 11 disposed on its inner wall corresponding to the first input terminal 221 and the second input terminal 222 . The housing 1 is provided with a cooling channel 5 containing a coolant, and the cooling channel 5 is located below the power module 4 and the supporting capacitor 3 .

[0084] An insulating layer is respectively provided between the first input terminal 221 and the second input terminal 222 and the heat dissipation boss 11 . Optionally, the insulating layer may be a heat conducting layer 6 .

[0085] Combination Figure 5 and Figure 6 As shown, in this embodiment, the cooling channel 5 does not pass through the motor controller under the high-voltage filter 2. The coolant flows from the liquid inlet pipe 54 into the cooling channel 5 under the supporting capacitor 3, and successively flows through the cooling channel 5 under the supporting capacitor 3 and the cooling channel 5 under the power module 4, thereby gradually cooling the high-voltage filter 2, the supporting capacitor 3 and the power module 4.

[0086] A part of the heat generated by the first input terminal 221 and the second input terminal 222 under large current is dissipated into the air through heat dissipation, and most of the heat is transferred to the heat dissipation boss 11 through the heat conductive layer 6, and then transferred to the shell 1 by the heat dissipation boss 11. That is, a small part of the heat on the shell 1 is dissipated into the air through heat dissipation, and most of the heat is taken away by the coolant through thermal convection between the shell 1 and the coolant.

[0087] The coolant flows from the liquid inlet pipe 54 into the cooling channel 5 below the support capacitor 3, and then flows through the cooling channel 5 below the power module 4 to cool the support capacitor 3 and the power module 4. A portion of the heat generated by the first input terminal 221 and the second input terminal 222 of the high-voltage filter 2 under large current is dissipated into the air through thermal convection and thermal radiation, and most of it is transferred to the heat dissipation boss 11 through the heat conductive layer 6, and then transferred to the housing 1 by the heat dissipation boss 11. A small portion of the heat on the housing 1 is dissipated into the air through thermal convection and thermal radiation, and most of the heat is taken away by the coolant through thermal convection between the housing 1 and the coolant. In this solution, the heat of the first input terminal 221 and the second input terminal 222 of the high-voltage filter 2 needs to be transferred to the bottom of the support capacitor 3, and then the heat of the first input terminal 221 and the second input terminal 222 is transferred to the coolant through heat dissipation.

[0088] In the high-voltage filter 2, the first input terminal 221 and the second input terminal 222 act as heating elements, and there is convection heat transfer and radiation heat transfer between their surfaces and the air. Convection heat transfer refers to the transfer of heat from the copper bar surface to the air through air flow, while thermal radiation refers to the transfer of heat by the copper bar surface directly emitting electromagnetic waves into space. These two methods work together to dissipate part of the heat generated by the copper bar under high current into the air, thereby keeping the temperature of the first input terminal 221 and the second input terminal 222 within a relatively safe range.

[0089] In some optional embodiments, the cooling channel 5 includes a connected capacitor cooling sub-channel 52 and a power cooling sub-channel 53. Along the direction Z pointing from the input terminal 22 to one side of the heat dissipation boss 11, the orthographic projection of the capacitor cooling sub-channel 52 overlaps with the orthographic projection of the supporting capacitor 3, and the orthographic projection of the power cooling sub-channel 53 overlaps with the orthographic projection of the power module 4.

[0090] Specifically, the cooling channel 5 includes a capacitor cooling sub-channel 52 and a power cooling sub-channel 53. The capacitor cooling sub-channel 52 is located below the supporting capacitor 3, and the power cooling sub-channel 53 is located below the power module 4. The power cooling sub-channel 53 is connected to the capacitor cooling sub-channel 52, which is conducive to the coolant entering from the liquid inlet pipe 54, taking away the heat generated on the supporting capacitor 3 and the power module 4 in turn, and then going out from the liquid outlet pipe 55.

[0091] Optionally, combined Figure 5 and Figure 6As shown, the cooling channel 5 has a connected liquid inlet pipe 54 and a liquid outlet pipe 55, the liquid inlet pipe 54 is located below the capacitor cooling sub-channel 52 and close to the side of the high-voltage filter 2, and the liquid outlet pipe 55 is located on the side of the power cooling sub-channel 53 away from the high-voltage filter 2. Since the liquid inlet pipe 54 is closer to the side of the high-voltage filter 2, the coolant first passes under the support capacitor 3 close to the side of the high-voltage filter 2, which more effectively improves the heat dissipation effect of the high-voltage filter 2, such as reducing the temperature of the filter capacitor 20 of the high-voltage filter 2 to below 110°C, which can prevent the filter capacitor 20 of the high-voltage filter 2 from being damaged due to exceeding the working temperature, that is, improve the service life of the filter capacitor 20, thereby ensuring the operation of the high-voltage filter 2. Optionally, the liquid inlet pipe 54 and the liquid outlet pipe 55 are arranged opposite to each other, such as the liquid inlet pipe 54 is located on the front side of the housing 1, and its opening faces the front side, and the liquid outlet pipe 55 is located on the rear side of the housing 1, and its opening faces the rear side.

[0092] Optionally, refer to Figure 7 As shown, the cooling channel 5 has a connected liquid inlet pipe 54 and a liquid outlet pipe 55, the liquid inlet pipe 54 is located below the power module 4 and away from the side of the high-voltage filter 2, and the liquid outlet pipe 55 is located on the side of the support capacitor 3 close to the high-voltage filter 2. In this solution, the coolant first passes through the bottom of the power module 4, which can greatly improve the heat dissipation effect of the power module 4. Due to the local temperature reduction in the housing 1, the heat generated by the first input terminal 221 and the second input terminal 222 in the subsequent high-voltage filter 2 is transferred to the low temperature, which can also improve the heat dissipation effect of the first input terminal 221 and the second input terminal 222 in the high-voltage filter 2, thereby preventing the filter capacitor 20 of the high-voltage filter 2 from being damaged due to exceeding the operating temperature. Optionally, the liquid inlet pipe 54 and the liquid outlet pipe 55 are arranged opposite to each other, such as the liquid inlet pipe 54 is located at the rear side of the housing 1, and its opening faces the rear side, and the liquid outlet pipe 55 is located at the front side of the housing 1, and its opening faces the front side.

[0093] In some optional embodiments, continue to refer to Figure 6 As shown, the shell 1 includes a first part 12 and a second part 13 connected to the first part 12, the second part 13 is located below the first part 12, the accommodating space 10 is located in the first part 12, the cooling channel 5 is located in the second part 13, the second part 13 includes a first layer 131 and a second layer 132 connected to the first layer 131, the first layer 131 is connected to the first part 12, and the cooling channel 5 is located between the first layer 131 and the second layer 132. It can be understood that the second part 13 of the shell 1 is a double-layer structure, and the coolant flows between the first layer 131 and the second layer 132, which is beneficial to take away the heat generated by the high-voltage filter 2, the supporting capacitor 3 and the power module 4.

[0094] Optionally, combined Figure 5 and Figure 6As shown, the high-voltage filter 2, the supporting capacitor 3 and the power module 4 are respectively fixed to the first part 12 by fasteners (not shown in the figure) and screw holes 7, so that the high-voltage filter 2, the supporting capacitor 3 and the power module 4 are respectively effectively fixed to the housing 1, and the overall structure is simple and easy to operate. The above-mentioned fasteners can be screws, which are a common fastener. The high-voltage filter 2, the supporting capacitor 3 and the power module 4 can be reinforced with the housing 1 by screws, so as to improve the stability and safety between the high-voltage filter 2, the supporting capacitor 3 and the power module 4 and the housing 1, and ensure the normal use and operation of the high-voltage filter 2, the supporting capacitor 3 and the power module 4.

[0095] Optionally, continue to refer to Figure 6 As shown, along the direction X pointing from the power module 4 to the side of the high-voltage filter 2, the cross-sectional area of ​​the heat dissipation boss 11 close to the thermal conductive layer 6 is smaller than the cross-sectional area of ​​the thermal conductive layer 6 close to the heat dissipation boss 11. Since the thermal conductive layer 6 is in direct contact with the first input terminal 221 and the second input terminal 222, by increasing the contact area between the first input terminal 221 and the second input terminal 222 and the thermal conductive layer 6, the heat generated by the first input terminal 221 and the second input terminal 222 can be quickly transferred to the heat dissipation boss 11, thereby taking away the heat generated by the first input terminal 221 and the second input terminal 222. At the same time, the input terminal 22 can be prevented from directly contacting the heat dissipation boss 11, so as to achieve the purpose of effective insulation.

[0096] It should be noted that the structure of the heat dissipation boss 11, the coolant, the temperature of the coolant, the material of the thermal conductive layer 6, and the thickness of the thermal conductive layer 6 in this embodiment are the same as the structure of the heat dissipation boss 11, the coolant, the temperature of the coolant, the material of the thermal conductive layer 6, and the thickness of the thermal conductive layer 6 in Example 1, and will not be repeated here.

[0097] It should be noted that: in another embodiment of the present invention, along the direction Z pointing from the input terminal 22 to the side of the heat dissipation boss 11, only the orthographic projection of the high-voltage filter 2 overlaps with the orthographic projection of the cooling channel 5; in another embodiment of the present invention, along the direction Z pointing from the input terminal 22 to the side of the heat dissipation boss 11, only the orthographic projection of the supporting capacitor 3 overlaps with the orthographic projection of the cooling channel 5; in another embodiment of the present invention, along the direction Z pointing from the input terminal 22 to the side of the heat dissipation boss 11, only the orthographic projection of the power module 4 overlaps with the orthographic projection of the cooling channel 5.

[0098] Embodiment 3

[0099] The present invention provides a vehicle, and the vehicle comprises the above-mentioned motor controller.

[0100] Although some specific embodiments of the present invention have been described in detail by way of example, it will be appreciated by those skilled in the art that the above examples are for illustration only and are not intended to limit the scope of the present invention. It will be appreciated by those skilled in the art that the above embodiments may be modified without departing from the scope and spirit of the present invention. The scope of the present invention is defined by the appended claims.

Claims

1. A motor controller, characterized in that: It includes a housing, a high-voltage filter, a supporting capacitor and a power module, wherein: The housing has a containing space inside, and the high-voltage filter, the supporting capacitor and the power module are horizontally arranged in the containing space; The high-voltage filter comprises input terminals arranged at intervals, the input terminals are electrically connected to the filter capacitor, and the ends of the input terminals are exposed; The housing has an inner wall provided with heat dissipation bosses distributed at intervals, the exposed input terminals correspond to the heat dissipation bosses, and the input terminals are located above the heat dissipation bosses; The housing has a bottom wall provided with a cooling channel containing a coolant, and the cooling channel is located below the high-voltage filter, the supporting capacitor and / or the power module; Along the direction from the input terminal to one side of the heat dissipation boss, the orthographic projection of the power module, the supporting capacitor and / or the high-voltage filter at least partially overlaps with the orthographic projection of the cooling channel.

2. The motor controller according to claim 1, characterized in that: Along the direction from the input terminal to one side of the heat dissipation boss, the orthographic projections of the high-voltage filter, the support capacitor and the power module overlap with the orthographic projection of the cooling channel.

3. The motor controller according to claim 2, characterized in that: The cooling channel comprises a filter cooling sub-channel, a capacitor cooling sub-channel and a power cooling sub-channel which are connected to each other; Along the direction from the input terminal to one side of the heat dissipation boss, the orthographic projection of the filter cooling sub-channel overlaps with the orthographic projection of the high-voltage filter, the orthographic projection of the capacitor cooling sub-channel overlaps with the orthographic projection of the supporting capacitor, and the orthographic projection of the power cooling sub-channel overlaps with the orthographic projection of the power module.

4. The motor controller according to claim 3, characterized in that: The cooling channel comprises a liquid inlet pipe and a liquid outlet pipe which are connected to each other, wherein the liquid inlet pipe is located on a side of the filter cooling sub-channel away from the capacitor cooling sub-channel, and the liquid outlet pipe is located on a side of the power cooling sub-channel away from the capacitor cooling sub-channel; or, The liquid inlet pipe is located at a side of the power cooling sub-channel away from the capacitor cooling sub-channel, and the liquid outlet pipe is located at a side of the filter cooling sub-channel away from the capacitor cooling sub-channel.

5. The motor controller according to claim 1, characterized in that: Along the direction from the input terminal to one side of the heat dissipation boss, the orthographic projection of the power module and the orthographic projection of the support capacitor overlap with the orthographic projection of the cooling channel respectively.

6. The motor controller according to claim 5, characterized in that: The cooling channel includes a capacitor cooling sub-channel and a power cooling sub-channel that are connected to each other. Along the direction from the input terminal to one side of the heat dissipation boss, the orthographic projection of the capacitor cooling sub-channel overlaps with the orthographic projection of the supporting capacitor, and the orthographic projection of the power cooling sub-channel overlaps with the orthographic projection of the power module.

7. The motor controller according to claim 1, characterized in that: The housing comprises a first part and a second part connected to the first part, the accommodation space is located in the first part, and the second part is located at a side of the first part away from the accommodation space; The second part includes a first layer and a second layer connected to the first layer, the first layer is connected to the first part, and the cooling channel is formed between the first layer and the second layer.

8. The motor controller according to claim 1, characterized in that: A heat-conducting layer is arranged between the input terminal and the heat-dissipating boss, and the material of the heat-conducting layer includes a heat-conducting insulating material.

9. The motor controller according to claim 8, characterized in that: Along the direction from the power module to the side of the high-voltage filter, the cross-sectional area of ​​the heat dissipation boss close to the heat conductive layer is smaller than the cross-sectional area of ​​the heat conductive layer close to the heat dissipation boss.

10. A vehicle, characterized in that: Comprising the motor controller according to any one of claims 1-9.

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