Power conversion and distribution unit, drive system, and vehicle

Abstract

The invention relates to a power conversion and distribution unit, a driving system and a vehicle. The power conversion and distribution unit includes: a first housing having an open first opening and having a first electrical component disposed therein; the second shell is provided with a second opening, and a second electrical component is arranged in the second shell; the first shell and the second shell are stacked in the mode that the first opening and the second opening are in butt joint with each other.

Description

Technical Field

[0001] The present disclosure relates to a power conversion and distribution unit, a drive system, and a vehicle. Background Art

[0002] With the country's promotion of energy conservation and emission reduction and the demand for controlling air pollution, the electric vehicle market is growing rapidly, and electric vehicles will become the mainstream products in the future automobile market. On-board chargers (OBC), DC-DC converters, inverters, high-voltage power distributors (PDU), high-voltage DC power supplies (HCDC), fuses, relays, electric heaters (PTC), fast chargers, compressor controllers, etc. are important components of electric vehicle drive systems.

[0003] With the development of technology, in recent years, the above components have been integrated into the housing and then installed on the housing of the reducer and the motor. Considering the different functions and failure rates of the above components, the above components are usually installed in different housings to facilitate assembly, disassembly and maintenance. However, the vibration amplitude of the large and flat housing cover is large, which will generate a lot of noise, thus deteriorating the NVH performance of the vehicle. Summary of the invention

[0004] Therefore, the purpose of the present disclosure is to provide a power conversion and distribution unit, a drive system and a vehicle, wherein the power conversion and distribution unit does not use a large and flat cover, the assembly, disassembly and maintenance of the components in the drive system are simple and convenient, and it has a smaller size, reduced cost, improved NVH performance and better EMC performance.

[0005] The above objects are achieved by the power conversion and distribution unit, the drive system and the vehicle described below.

[0006] The present disclosure relates to an electric power conversion and distribution unit, comprising: a first shell having an open first opening and a first electrical component disposed therein; a second shell having an open second opening and a second electrical component disposed therein; wherein the first shell and the second shell are stacked in such a manner that the first opening and the second opening are butted against each other.

[0007] In one embodiment, the power conversion and distribution unit further includes a seal, and the seal is disposed between the first shell and the second shell.

[0008] In one embodiment, the first shell has a first lateral extension portion located at the first opening, the second shell has a second lateral extension portion located at the second opening, and the first lateral extension portion and the second lateral extension portion are connected to each other via a fixing member.

[0009] In one embodiment, the first electrical component is disposed on the bottom wall of the first housing, and the second electrical component is disposed on the bottom wall of the second housing.

[0010] In one embodiment, the first shell accommodates a first circuit board assembly, and a first support column is provided on the bottom wall of the first shell for supporting the first circuit board assembly; the second shell accommodates a second circuit board assembly, and a second support column is provided on the bottom wall of the second shell for supporting the second circuit board assembly.

[0011] In one embodiment, the first supporting column is located around the first electrical component, and the second supporting column is located around the second electrical component.

[0012] In one embodiment, the power conversion and distribution unit further includes a shielding component, wherein the shielding component is located between the first circuit board assembly and the second circuit board assembly.

[0013] In one embodiment, a third support column is provided on the bottom wall of the first shell or the second shell for supporting the shielding component; or the shielding component is supported in the first shell or the second shell by the first support column or the second support column; or the shielding component is clamped between the first shell and the second shell by a fixing member.

[0014] In one embodiment, the power conversion and distribution unit further includes a cooling channel, and the cooling channel includes a first channel portion provided on the bottom wall of the first shell and a second channel portion provided on the bottom wall of the second shell.

[0015] In one embodiment, the cooling channel further includes a third channel portion disposed on the side wall of the first shell and a fourth channel portion disposed on the side wall of the second shell, and the third channel portion and the fourth channel portion are in fluid communication.

[0016] In one embodiment, the first shell is located above the second shell, and a joint surface between the third flow channel portion and the fourth flow channel portion is lower than a joint surface between the first shell and the second shell.

[0017] In one embodiment, reinforcing ribs are provided on the outer wall of the first shell and / or the second shell.

[0018] In one embodiment, the first electrical component includes a DCDC converter and an on-board charger, and the second electrical component includes a motor controller.

[0019] The present disclosure also relates to a driving system, which includes a motor, a reducer, and the power conversion and distribution unit as described above, wherein the power conversion and distribution unit is arranged on the motor and the reducer.

[0020] The present disclosure also relates to a vehicle, which comprises the drive system as described above.

[0021] The advantageous effects of the embodiments of the present disclosure are that assembly, disassembly and maintenance are simple and convenient, the size is small, the cost is low, the basic functions can be guaranteed not to be affected by component damage, and the NVH performance and EMC performance are better. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The advantages and purposes of the present disclosure can be better understood from the preferred embodiments of the present disclosure described in detail below in conjunction with the accompanying drawings. In order to better show the relationship between the various components in the accompanying drawings, the accompanying drawings are not drawn to scale. In the accompanying drawings:

[0023] Figure 1 A schematic cross-sectional view showing a power conversion and distribution unit for a driving system of a vehicle according to one embodiment of the present disclosure is shown; and

[0024] Figure 2 An external schematic diagram of a power conversion and distribution unit for a driving system of a vehicle according to an embodiment of the present disclosure is shown. DETAILED DESCRIPTION

[0025] In order to make the purpose, technical solution and advantages of the technical solution of the present disclosure clearer, the technical solution of the embodiment of the present disclosure will be clearly and completely described in combination with the drawings of the specific embodiments of the present disclosure. The same figure marks in the drawings represent the same parts. It should be noted that the described embodiments are part of the embodiments of the present disclosure, not all of the embodiments. Based on the described embodiments of the present disclosure, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present disclosure.

[0026] Unless otherwise defined, the technical terms or scientific terms used herein shall have the usual meanings understood by persons with ordinary skills in the field to which the present disclosure belongs. The words "first", "second" and similar words used in the patent application specification and claims of the present disclosure do not indicate any order, quantity or importance, but are only used to distinguish different components. Similarly, words such as "one" or "one" do not necessarily indicate a quantity limitation. Words such as "include", "comprise" or "have" mean that the elements or objects appearing before the word include the elements or objects listed after the word and their equivalents, without excluding other elements or objects. Words such as "connect" or "connected" are not limited to the physical or mechanical connections or connections shown in the drawings, but may include connections or connections equivalent thereto, whether direct or indirect. "Up", "down", "left", "right" and the like are only used to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0027] Below, see Figure 1 to Figure 2 Various embodiments of the present disclosure are described in detail.

[0028] The driving system included in the vehicle according to the present disclosure includes a motor and a reducer, and may also include Figure 1 and 2 The power conversion and distribution unit is shown. The power conversion and distribution unit is arranged close to the motor and the reducer, for example, the power conversion and distribution unit is arranged on the motor and the reducer, specifically on the top of the motor and the reducer.

[0029] like Figure 1 and 2 As shown, the power conversion and distribution unit includes a first housing 1 and a second housing 2. The first housing 1 has an open first opening and a first electrical component 3 is disposed therein. The second housing 2 has an open second opening and a second electrical component 4 is disposed therein. The first housing 1 and the second housing 2 are stacked in a manner that the first opening and the second opening are butted against each other. Figure 1 As shown, the first shell 1 and the second shell 2 both have a U-shaped cross-section, and the first shell 1 is butted against the second shell 2 in an inverted manner. With this arrangement, the cover of the first shell 1 and the cover of the second shell 2 can be omitted, which can not only reduce the volume of the power conversion and distribution unit, but also improve the NVH performance of the vehicle.

[0030] In some embodiments, the first electrical component 3 may include a DCDC converter and an on-board charger (OBC), and the second electrical component 4 may include a motor controller.

[0031] In some embodiments, the first electrical component 3 may also include a fast charger, etc., and the second electrical component 4 may also include at least one of the following: a power distributor (for example, a high-voltage power distributor, i.e., PDU), a high-voltage direct current power supply (HVDC), an electric heater (PTC), etc.

[0032] The motor controller is an inverter that converts the DC power stored in the power battery into variable-frequency and variable-voltage AC power to control the speed and torque of the motor. The vehicle's inverter adjusts the amplitude and frequency of the AC power. The frequency controls the speed of the vehicle, and the amplitude controls the power of the vehicle.

[0033] The DC-DC converter can convert the DC power supply voltage into any DC voltage to provide the required power for the power steering system, the air conditioner in the vehicle, and other auxiliary equipment. The DC-DC converter receives input from the power battery and powers the on-board electrical appliances. For example, the DC-DC converter can output a low voltage of about 12V, which can power a low-voltage battery.

[0034] The on-board charger is an energy conversion device used to control and adjust the charging of the power battery on the vehicle. The grid voltage is input into the on-board charger through the ground AC charging pile and AC charging port, and then the power battery is charged.

[0035] The power distributor or high-voltage power distributor (Power Distribution Unit) is connected to the vehicle's power battery, motor controller, inverter, etc., and provides charging and discharging control, high-voltage component power-on control, circuit overload and short-circuit protection, high-voltage sampling, low-voltage control and other functions for the vehicle's high-voltage system to protect and monitor the operation of the high-voltage system.

[0036] The electric heater (Positive Temperature Coefficient) is a thermistor that generates heat when powered to heat the air passing through it, thereby providing adjustable warm air and glass defogger and defrost functions.

[0037] The distribution of the above components in the first housing and the second housing can be carried out according to the functions and / or failure rates of the electrical components. By assembling in different housings, the removal and replacement of electrical components, especially inverters, DCDC converters and on-board chargers can be carried out separately. Specifically, the installation of the first electrical component is independent of the installation of the second component, and the first housing and the second housing are assembled together after the first component is installed in the first housing and the second component is installed in the second housing. By arranging the DCDC converter and the on-board charger with a relatively high failure rate in the first housing 1 located above, the assembly, disassembly and maintenance of the system are simple, convenient and low-cost, and the basic functions can be guaranteed to be unaffected by component damage. Specifically, when the first electrical component 3 including the DCDC converter and the on-board charger is damaged, the inverter located in the second electrical housing 2 can still ensure that the drive system works for a period of time and ensures basic functions. For example, when the DCDC converter and the on-board charger are removed or replaced, the drive system can still work normally without being affected.

[0038] The power conversion and distribution unit further includes a seal 7, which is disposed between the first housing 1 and the second housing 2. Specifically, the seal 7 can be disposed between the joint surfaces of the first housing and the second housing. For example, the seal 7 is a sealing ring made of an elastic material or a sealant, and the present disclosure does not limit the material thereof.

[0039] The first housing 1 has a first lateral extension 8 at the first opening, and the second housing 2 has a second lateral extension 9 at the second opening. The first lateral extension 8 and the second lateral extension 9 are connected to each other by a fixing member. The lateral extension here refers to a portion extending laterally from the side wall of the corresponding housing. Figure 2 As shown, a plurality of threaded holes are respectively provided on the first lateral extension portion 8 and the second lateral extension portion 9 , and the first lateral extension portion 8 and the second lateral extension portion 9 are connected together by bolts or screws.

[0040] See again Figure 1 The contact surfaces of the first lateral extension portion 8 and the second lateral extension portion 9 may be respectively provided with grooves for accommodating the seal 7 , or one of the two may be provided with a groove for accommodating the seal 7 .

[0041] The first electrical component 3 is arranged on the bottom wall of the first housing 1, or on the top wall of the whole formed by the first housing 1 and the second housing 2. The second electrical component 4 is arranged on the bottom wall of the second housing 2, or on the bottom wall of the whole formed by the first housing 1 and the second housing 2. For example, the electrical components can be fixed to the bottom walls of their respective housings by means of threaded connection or bonding.

[0042] In addition, if Figure 1As shown, the first housing 1 accommodates the first circuit board assembly 5, and the first support column 10 is provided on the bottom wall of the first housing 1 for supporting the first circuit board assembly 5; the second housing 2 accommodates the second circuit board assembly 6, and the second support column 11 is provided on the bottom wall of the second housing 2 for supporting the second circuit board assembly 6. The first circuit board assembly 5 is provided with a circuit for controlling the first electrical component 3, and the second circuit board assembly 6 is provided with a circuit for controlling the second electrical component 4. For example, the first circuit board assembly 5 and the second circuit board assembly 6 can each include a plurality of circuit boards, which are stacked in the corresponding housing. The first support column 10 can be located around the first electrical component 3. The second support column 11 can be located around the second electrical component 4. For example, the first support column 10 and the second support column 11 can be formed integrally with the corresponding housing. By providing the support column, the circuit board assembly can be stacked above the corresponding electrical component, thereby achieving a more compact design. Of course, the circuit board assembly of the present disclosure can also be provided in the corresponding housing in other ways, such as a support member provided on the side wall of the corresponding housing.

[0043] like Figure 1 As shown, the power conversion and distribution unit may further include a shielding component 12, and the shielding component 12 is located between the first circuit board assembly 5 and the second circuit board assembly 6. For example, a third support column 13 is provided on the bottom wall of the first housing 1 or the second housing 2 for supporting the shielding component 7. The setting position of the third support column 13 can be determined according to the positions of the electrical components and the first support column and the second support column in the housing. In some other examples, the shielding component 7 is supported in the first housing 1 or the second housing 2 by the first support column 10 or the second support column 11, which can further reduce the volume and save costs. In some other examples, the shielding component 7 is clamped between the first housing 1 and the second housing 2 by a fixing member. For example, the shielding component 7 can be formed by a metal plate. When the thickness of the metal plate is moderate, the first housing 1 and the second housing 2 can be fixed on the shielding component 7, and the fixing member used to connect the first housing and the second housing can also be used to fix the shielding component 7. By providing the shielding component 7, better EMC performance can be provided, and when the first housing 1 located above is removed or the first electrical component in the first housing 1 is repaired, protection can be provided for the second electrical component (especially the inverter) provided in the second housing 2.

[0044] like Figure 1 As shown by the dotted arrows in , the power conversion and distribution unit further includes a cooling channel, which includes a first channel portion 14 disposed on the bottom wall of the first housing 1 and a second channel portion 15 disposed on the bottom wall of the second housing 2. The first channel portion 14 and the second channel portion 15 may be fluidically connected to each other, such as through a pipe, or may not be fluidically connected. By arranging the cooling channel close to the electrical components, efficient cooling can be achieved.

[0045] like Figure 2 As shown, the cooling channel also includes a cooling inlet 19 located at one end of the second channel portion 15 and a cooling outlet 20 located at one end of the first channel portion 14. The cooling inlet 19 and the cooling outlet 20 can be interchanged, that is, the cooling inlet serves as the outlet and the cooling outlet serves as the inlet. For example, the cooling fluid can flow in from the cooling inlet 19, flow through the second channel portion 15 and the first channel portion 14, and then flow out from the cooling outlet 20, for example, into the motor housing.

[0046] See again Figure 1 The cooling channel further includes a third channel portion 16 disposed on the side wall of the first shell 1 and a fourth channel portion 17 disposed on the side wall of the second shell 2, and the third channel portion 16 and the fourth channel portion 17 are in fluid communication. Figure 1 As shown by the dotted arrow in FIG. 1 , the cooling fluid flows in from the cooling inlet 19, flows through the second flow channel portion 15, the fourth flow channel portion 17, the third flow channel portion 16 and the first flow channel portion 14 in sequence, and then flows out from the cooling outlet 20. Of course, the cooling fluid can also flow in the opposite direction.

[0047] Figure 1 The first shell 1 shown in the figure is located above the second shell 2, and the joint surface of the third flow channel portion 16 and the fourth flow channel portion 17 is lower than the joint surface of the first shell 1 and the second shell 2. When the first shell 1 located above needs to be removed, the cooling fluid can be prevented from flowing into the shell (especially the second shell 2). Of course, the joint surface of the third flow channel portion 16 and the fourth flow channel portion 17 can also be higher than the joint surface of the first shell 1 and the second shell 2, which depends on the specific design requirements.

[0048] The cooling fluid mentioned above can be water or oil. In the case of using oil as the cooling fluid, the oil flows to the reducer housing and / or the motor housing after flowing through the power conversion and distribution unit as described above.

[0049] See again Figure 2 , reinforcing ribs 18 are provided on the outer wall of the first shell 1 and / or the second shell 2. This makes the shell stronger and has a thicker wall, thereby further improving the NVH performance.

[0050] The above-mentioned power conversion and distribution unit disclosed in the present invention does not use a large and flat cover, and the assembly, disassembly and maintenance of the components in the drive system are simple and convenient, and has a smaller size, reduced cost, improved NVH performance and better EMC performance.

[0051] The drive system and vehicle disclosed in the present invention have corresponding advantages. According to another aspect of the present invention, the vehicle includes the drive system and the power conversion and distribution unit as described above, and has the functions as described above. The vehicle can be an electrified vehicle (Electrified Vehicle), such as a pure electric vehicle (BEV, Battery Electric Vehicle), a hybrid electric vehicle (HEV, Hybrid Electric Vehicle), a plug-in hybrid electric vehicle (PHEV, Plug-in Hybrid Electric Vehicle), an extended-range electric vehicle (Range extended EV), and a fuel cell vehicle (FCEV, Fuel Cell Electric Vehicle). The vehicle can also be a hydrogen energy vehicle.

[0052] In addition, the technical features disclosed above are not limited to the disclosed combinations with other features. Those skilled in the art may also make other combinations between the technical features according to the purpose of disclosure to achieve the purpose of this disclosure.

Claims

1. A power conversion and distribution unit, characterized in that: include: A first housing (1) having an open first opening and containing a first electrical component (3); A second housing (2) having an open second opening and containing a second electrical component (4); The first shell (1) and the second shell (2) are stacked in a manner such that the first opening and the second opening are butted against each other.

2. The power conversion and distribution unit according to claim 1, characterized in that: The power conversion and distribution unit further comprises a sealing member (7), which is arranged between the first shell (1) and the second shell (2).

3. The power conversion and distribution unit according to claim 1, characterized in that: The first shell (1) has a first lateral extension portion (8) located at the first opening, and the second shell (2) has a second lateral extension portion (9) located at the second opening, and the first lateral extension portion and the second lateral extension portion are connected to each other via a fixing member.

4. The power conversion and distribution unit according to claim 1, characterized in that: The first electrical component (3) is arranged on the bottom wall of the first shell (1), and the second electrical component (4) is arranged on the bottom wall of the second shell (2).

5. The power conversion and distribution unit according to claim 4, characterized in that: The first housing (1) accommodates a first circuit board assembly (5); a first supporting column (10) is provided on the bottom wall of the first housing (1) for supporting the first circuit board assembly (5); The second housing (2) accommodates a second circuit board assembly (6), and a second support column (11) is provided on the bottom wall of the second housing (2) for supporting the second circuit board assembly (6).

6. The power conversion and distribution unit according to claim 5, characterized in that: The first support column (10) is located around the first electrical component (3), and the second support column (11) is located around the second electrical component (4).

7. The power conversion and distribution unit according to claim 5, characterized in that: The power conversion and distribution unit further comprises a shielding component (12), which is located between the first circuit board assembly (5) and the second circuit board assembly (6).

8. The power conversion and distribution unit according to claim 7, characterized in that: A third supporting column (13) is provided on the bottom wall of the first shell (1) or the second shell (2) for supporting the shielding component (7); or The shielding component (7) is supported in the first shell (1) or the second shell (2) by the first supporting column (10) or the second supporting column (11); or The shielding component (7) is clamped between the first shell (1) and the second shell (2) by a fixing member.

9. The power conversion and distribution unit according to claim 1, characterized in that: The power conversion and distribution unit further comprises a cooling channel, wherein the cooling channel comprises a first channel portion (14) arranged on the bottom wall of the first shell (1) and a second channel portion (15) arranged on the bottom wall of the second shell (2).

10. The power conversion and distribution unit according to claim 9, characterized in that: The cooling channel further comprises a third channel portion (16) arranged on the side wall of the first shell (1) and a fourth channel portion (17) arranged on the side wall of the second shell (2), and the third channel portion and the fourth channel portion are fluidically connected.

11. The power conversion and distribution unit according to claim 10, characterized in that: The first shell (1) is located above the second shell (2), and the joint surface of the third flow channel portion (16) and the fourth flow channel portion (17) is lower than the joint surface of the first shell (1) and the second shell (2).

12. The power conversion and distribution unit according to claim 1, characterized in that: Reinforcing ribs (18) are provided on the outer walls of the first shell (1) and / or the second shell (2).

13. The power conversion and distribution unit according to claim 10, characterized in that: The first electrical component (3) includes a DCDC converter and an on-board charger, and the second electrical component (4) includes a motor controller.

14. A drive system, characterized in that: The driving system includes a motor, a reducer, and a power conversion and distribution unit according to any one of claims 1 to 13, wherein the power conversion and distribution unit is arranged on the motor and the reducer.

15. A vehicle, characterized in that: The vehicle includes the drive system of claim 14.

Images