Motor controller

Abstract

The invention relates to the technical field of motors, and particularly provides a motor controller. The motor controller aims to solve one or more problems of long assembly time and low assembly efficiency of an existing motor controller or large size and low power density of the existing motor controller. Therefore, the motor controller comprises a shell assembly, a power module, a mainboard assembly and an integrated non-magnetic-core current sensor AC assembly, a first containing cavity is formed in the shell assembly, and the power module and the mainboard assembly are located in the first containing cavity; one part of the integrated non-magnetic-core current sensor AC assembly is located in the first containing cavity, the other part of the integrated non-magnetic-core current sensor AC assembly extends out of the first containing cavity and forms an AC output port, and the power module, the mainboard assembly and the integrated non-magnetic-core current sensor AC assembly are all riveted with the shell assembly in a rotary riveting mode. The motor controller is convenient to assemble, high in assembling efficiency, small in size and large in power density.

Description

Technical Field

[0001] The present application relates to the field of motor technology and specifically provides a motor controller. Background Art

[0002] At present, the motor controller in the vehicle electric drive system is integrated with the power module for DC-AC conversion, DC filter, bus capacitor, control board, drive board, radiator assembly, high voltage input, low voltage output, three-phase AC output, current-carrying copper bus, shell, cover plate, bolts and other devices. Its integration methods include flat and vertical. Among them, the flat integration method simply places the filter, capacitor, power module, three-phase AC output, control board, and drive board in general and seals them with a shell, which reduces the overall thickness of the controller, increases the length and width, and wastes a lot of space. The vertical integration method places important components vertically, reduces the length and width, and increases the overall thickness of the controller.

[0003] The above two integration methods only integrate some devices, and do not achieve synchronous integration and deep integration, which results in a low power density of the motor controller, which is basically below 100KW / L. Especially under the voltage trend of 800V, the electrical clearance requirement is greater, making this situation more prominent. In addition, bolts are used to assemble and fix each device during assembly and connection. The bolts need to be fixed one by one during the assembly process, which takes a long time and has low assembly efficiency.

[0004] Accordingly, this field requires a new technical solution to solve the above technical problems. Summary of the invention

[0005] The present application aims to solve the above-mentioned technical problems, that is, to solve one or more problems of the existing motor controllers, namely, long assembly time, low assembly efficiency, large size, and low power density.

[0006] The present application provides a motor controller, which includes a shell assembly, a power module, a mainboard assembly and an integrated coreless current sensor AC assembly. The shell assembly has a first accommodating cavity, the power module and the mainboard assembly are located in the first accommodating cavity, a portion of the integrated coreless current sensor AC assembly is located in the first accommodating cavity, and the other portion extends out of the first accommodating cavity to form an AC output port, and the power module, the mainboard assembly and the integrated coreless current sensor AC assembly are all riveted to the shell assembly.

[0007] In the preferred technical solution of the above-mentioned motor controller, the shell assembly includes a shell, a filter capacitor assembly and a potting resin, the shell has the first accommodating cavity and the second accommodating cavity connected to each other, the filter capacitor assembly is located in the second accommodating cavity, and the potting resin encapsulates the filter capacitor assembly in the second accommodating cavity, and the first end of the first current-carrying part of the filter capacitor assembly passes through the second accommodating cavity and is electrically connected to the power module; the power module, the mainboard assembly and the integrated coreless current sensor AC assembly are all riveted to the shell assembly, the mainboard assembly is located on the side of the power module away from the second accommodating cavity, the integrated coreless current sensor AC assembly is arranged close to one side wall of the shell, and a part of the integrated coreless current sensor AC assembly is located between the mainboard assembly and the power module.

[0008] In the preferred technical solution of the above-mentioned motor controller, a first external connector is provided on the shell, the first external connector includes a first connector shell formed on the shell and a first connector core located in the first connector shell, the first connector core includes a connector current-carrying member, the connector current-carrying member is electrically connected to a second current-carrying member of the filter capacitor assembly, and the second current-carrying member is electrically connected to the first current-carrying member; and / or a water inlet and a water outlet are provided on the shell.

[0009] In the preferred technical solution of the above motor controller, the first current-carrying component is a copper-aluminum composite bar; and / or, the plug-in current-carrying component is a copper-aluminum composite bar; and / or, the second current-carrying component is a copper-aluminum composite bar.

[0010] In the preferred technical solution of the above-mentioned motor controller, a plurality of first rivets, a plurality of second rivets and a plurality of third rivets are provided on the inner side wall of the shell, a first rivet hole corresponding to the position of the first rivet is provided on the power module, the first rivet is located in the first rivet hole, and the first rivet is riveted with the first rivet hole to fix the power module to the shell; a second rivet hole corresponding to the position of the second rivet is provided on the integrated coreless current sensor AC component, the second rivet is located in the second rivet hole, and the second rivet is riveted with the second rivet hole to fix the integrated coreless current sensor AC component to the shell; a third rivet hole corresponding to the position of the third rivet is provided on the mainboard component, the third rivet is located in the third rivet hole, and the third rivet is riveted with the third rivet hole to fix the mainboard component to the shell.

[0011] In the preferred technical solution of the above-mentioned motor controller, the first rotary rivet, the second rotary rivet and the third rotary rivet all include a connected supporting portion and a riveting portion, the outer diameter of the riveting portion is smaller than the outer diameter of the supporting portion, and the outer diameter of the supporting portion is larger than the hole diameter of the corresponding rotary rivet hole, the heights of the supporting portion of the first rotary rivet, the supporting portion of the second rotary rivet and the supporting portion of the third rotary rivet gradually increase, and in the axial direction of the rotary rivet, the position after the second rotary rivet is riveted with the second rotary rivet hole is between the position after the first rotary rivet is riveted with the first rotary rivet hole and the position after the third rotary rivet is riveted with the third rotary rivet hole.

[0012] In the preferred technical solution of the above-mentioned motor controller, the power module is provided with a first avoidance groove for the second rotary rivet to pass through and a second avoidance groove for the third rotary rivet to pass through; and / or the first rotary rivet, the second rotary rivet and the third rotary rivet are an integral structure with the shell.

[0013] In the preferred technical solution of the above-mentioned motor controller, the mainboard assembly includes an integrated board of a drive board and a control board, and a second plug-in core is integrated on the integrated board, a second plug-in shell is provided on the shell, and the second plug-in core and the second plug-in shell together form a second external plug-in.

[0014] In the preferred technical scheme of the above-mentioned motor controller, the power module is an embedded PCBA power module deeply integrated with the heat sink component, the first signal connection terminal and the third current carrier; the embedded PCBA power module is connected to the mainboard component through the first signal connection terminal, and the embedded PCBA power module is respectively connected to the first end of the first current carrier and the integrated coreless current sensor AC component through the third current carrier; and / or, the integrated coreless current sensor AC component is partially potted as a whole by three groups of output components, and an external sealing interface and an AC output port are formed at the output end of each group of the output components, each group of the output components includes a coreless current sensor and a fourth current carrier, the coreless current sensor is electrically connected to the fourth current carrier, the coreless current sensor is connected to the mainboard component through the second signal connection terminal, the first end of the fourth current carrier is electrically connected to the power module, the second end of the fourth current carrier passes through the external sealing structure to form the AC output port, and the three AC output ports are spaced apart in a straight line direction.

[0015] In the preferred technical solution of the above motor controller, the third current-carrying component is a copper-aluminum composite bar; and / or the fourth current-carrying component is a copper-aluminum composite bar.

[0016] When adopting the above technical solution, the motor controller of the present application includes a shell component, a power module, a mainboard component and an integrated coreless current sensor AC component, wherein the power module, the mainboard component and the integrated coreless current sensor AC component are located in the first accommodating cavity of the shell component, and a part of the integrated coreless current sensor AC component extends out of the first accommodating cavity and forms an AC output port, and the power module, the mainboard component and the integrated coreless current sensor AC component are all riveted to the shell component; this arrangement divides the motor controller into four independent large modules, namely the shell component, the power module, the mainboard component and the integrated coreless current sensor AC component, and only these four large modules need to be assembled. The shell assembly serves as a base to assemble and connect several other large modules, and the power module, the mainboard assembly and the integrated coreless current sensor AC assembly are all riveted to the shell assembly by rotary rivet. The rotary riveting machine is used for rotary riveting, which has fast speed, high efficiency and good stability of each part after assembly. In addition, the shell assembly, the power module, the mainboard assembly and the integrated coreless current sensor AC assembly are respectively integrated parts. The initial integration can reduce the volume of each large module. After that, the four large modules are integrated into a whole again, which can effectively utilize the space, thereby reducing the thickness and length and width of the motor controller, minimizing the volume of the motor controller, and then increasing the power density of the motor controller.

[0017] Furthermore, the shell assembly includes a shell, a filter capacitor assembly and a potting resin. The shell has a first accommodating cavity and a second accommodating cavity that are connected. The second accommodating cavity is used to integrate and fix the filter capacitor assembly. The potting resin integrates and encapsulates the filter capacitor assembly and its current-carrying parts for transmitting current in the second accommodating cavity of the shell. The first accommodating cavity is used to integrate and install the mainboard assembly, the power module and the integrated coreless current sensor AC assembly. The mainboard assembly is located on the side of the power module away from the second accommodating cavity, and the integrated coreless current sensor AC assembly is arranged close to one side wall of the shell, so that the filter capacitor assembly, the power module, the integrated coreless current sensor AC assembly partial area and the mainboard assembly are stacked vertically, and are respectively riveted to the shell assembly, thereby effectively utilizing the space of the first accommodating cavity of the shell assembly, which can better reduce the overall thickness of the motor controller, and then effectively reduce the volume of the motor controller to increase the power density.

[0018] Furthermore, a first external connector is provided on the shell, and the first external connector is an external connection interface for connecting to a power source to provide a high-voltage DC input for the motor controller.

[0019] Furthermore, a water inlet and a water outlet are provided on the shell body so as to install the water inlet and outlet pipes of the radiator assembly.

[0020] Furthermore, the plug-in current-carrying component, the first current-carrying component and the second current-carrying component are configured as a copper-aluminum composite bar, which can effectively reduce the weight of the motor controller and reduce the cost.

[0021] Furthermore, a first rivet, a second rivet and a third rivet are provided on the inner wall of the shell, and are respectively docked and riveted with the first rivet hole, the second rivet hole and the third rivet hole, so as to respectively fix the power module, the integrated coreless current sensor AC component and the mainboard component to the shell. The structure is simple, the fixing effect is good, the operation is simple, and the assembly and fixing are convenient.

[0022] Furthermore, the rotary rivet is divided into a supporting portion and a riveting portion, the outer diameter of the supporting portion is larger than the hole diameter of the rotary rivet hole connected thereto, and the heights of the supporting portions of the first rotary rivet, the second rotary rivet and the third rotary rivet are increased successively. In this arrangement, during the assembly process, after the riveting portion is inserted into the rotary rivet hole, the supporting portion abuts against the plate where the rotary rivet hole is located where it is connected thereto, thereby limiting the position of the device where the rotary rivet hole is located, and at the same time maintaining a specific electrical gap between the upper and lower adjacent devices, which is convenient for assembly and use, while ensuring the quality after assembly.

[0023] Furthermore, a first avoidance groove and a second avoidance groove are provided on the power module so that the second rivet and the third rivet can be smoothly docked and riveted with the integrated coreless current sensor AC component and the mainboard component to facilitate assembly.

[0024] Furthermore, the first rotary rivet, the second rotary rivet and the third rotary rivet are arranged as an integral structure with the shell, which is convenient for production and reduces cost.

[0025] Furthermore, the mainboard assembly includes an integrated board of a drive board and a control board. The integrated board is small in size, which helps to reduce the size of the motor controller, and a second plug-in core is integrated on the integrated board. The second plug-in core and the second plug-in shell of the shell together form a second external connector. The second external connector is a connection port of the mainboard assembly, which is used to power the mainboard assembly and to realize CAN communication connection between the motor controller and the vehicle control unit.

[0026] Furthermore, the power module is an embedded PCBA power module in which the embedded PCBA power module is deeply integrated with the heat sink assembly, the first signal connection terminal and the third current-carrying component. This arrangement deeply integrates the heat sink assembly, the embedded PCBA power module and the signal connection terminals and current connection terminals corresponding to the embedded PCBA power module, which can reduce the volume of the power module, thereby further reducing the overall volume of the assembled motor controller, and helping to improve the power density of the motor controller.

[0027] Furthermore, the integrated coreless current sensor AC component is partially potted as one by three groups of output components, and the output end of each group of output components forms an external sealing interface and an AC output port. Each group of output components includes a coreless current sensor and a fourth current-carrying component. This arrangement allows the three groups of output components to be potted as one by resin, which is convenient for assembling and connecting the three groups of output components at the same time, helping to improve assembly efficiency and arrange the three groups of output components in an orderly manner, helping to reduce the volume of the assembled motor controller, thereby increasing power density.

[0028] Furthermore, the third current-carrying component and the fourth current-carrying component are configured as copper-aluminum composite bars, which can reduce the weight of the motor controller and reduce the cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The preferred embodiments of the present application are described below in conjunction with the accompanying drawings, in which:

[0030] Figure 1 is a schematic diagram of the exploded structure of the motor controller of the present application;

[0031] Figure 2 is a schematic diagram of the three-dimensional structure of the motor controller of the present application;

[0032] Figure 3 is a bottom view of the motor controller of the present application;

[0033] Figure 4 yes Figure 3 Sectional view in the AA direction;

[0034] Figure 5 yes Figure 3 Cross-sectional view in the BB direction;

[0035] Figure 6 It is a three-dimensional structural schematic diagram of the shell assembly of the present application.

[0036] List of reference numerals:

[0037] 1. Shell assembly; 101. First accommodating cavity; 102. Second accommodating cavity; 103. Water inlet; 104. Water outlet; 11. Shell; 111. First spiral rivet; 112. Second spiral rivet; 113. Third spiral rivet; 114. External connection hole; 12. Filter capacitor assembly; 121. First current-carrying component; 122. Second current-carrying component; 13. Potting resin; 14. First external connector; 141. First connector housing; 142. First connector core; 1421. Connector current-carrying component; 15. Second external connector; 151. Second connector housing;

[0038] 2. Power module; 201. First rivet hole; 202. Positioning support column; 21. Embedded PCBA power module; 22. Radiator assembly; 23. First signal connection terminal; 24. Third current-carrying component;

[0039] 3. Mainboard assembly; 301. Third rivet hole; 31. Integrated board; 32. Second plug-in core;

[0040] 4. Integrated coreless current sensor AC component; 401. second rivet hole; 402. AC output port; 403. external sealing interface; 41. three-phase output component; 411. coreless current sensor; 412. fourth current-carrying component; 413. second signal connection terminal. DETAILED DESCRIPTION

[0041] The preferred embodiments of the present application are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only used to explain the technical principles of the present application and are not intended to limit the protection scope of the present application.

[0042] It should be noted that, in the description of the present application, the terms "first", "second", "third" and "fourth" are used for descriptive purposes only and should not be understood as indicating or implying relative importance.

[0043] In addition, it should be noted that in the description of this application, unless otherwise clearly specified and limited, the terms "set", "connect", and "install" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a direct connection or an indirect connection through other components. For those skilled in the art, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0044] Based on the problems pointed out in the background technology, the existing motor controller has a long assembly time, low assembly efficiency, large size and low power density.

[0045] The present application provides a motor controller. In the first aspect, the motor controller is divided into four independent large modules, namely a shell component, a power module, a mainboard component and an integrated coreless current sensor AC component. The shell component, the power module, the mainboard component and the integrated coreless current sensor AC component are respectively integrated parts, and their initial integration can reduce the volume of each large module. Thereafter, the four large modules are integrated into a whole again, which can effectively utilize the space, thereby reducing the thickness and length and width of the motor controller, minimizing the volume of the motor controller to the greatest extent, and thereby increasing the power density of the motor controller; in the second aspect, during assembly, only the four large modules need to be assembled, and the shell component is used as a base to assemble and connect the other large modules, and the power module, the mainboard component and the integrated coreless current sensor AC component are all riveted to the shell component by rotary rivets, and the rotary rivet riveting is performed by a rotary riveting machine, which has a fast speed, high efficiency, and good stability of each part after assembly.

[0046] For details, please also refer to Figures 1 to 6 The motor controller of the present application includes a housing component 1, a power module 2, a mainboard component 3 and an integrated coreless current sensor AC component 4.

[0047] Among them, the shell assembly 1 has a first accommodating cavity 101, the power module and the mainboard assembly 3 are located in the first accommodating cavity 101, a part of the integrated coreless current sensor AC assembly 4 is located in the first accommodating cavity 101, and the other part extends out of the first accommodating cavity 101 and forms an AC output port 402. The AC output port 402 is an interface for connecting the high-voltage AC with the motor. The power module 2, the mainboard assembly 3 and the integrated coreless current sensor AC assembly 4 are all riveted to the shell assembly 1.

[0048] The shell assembly 1 in the present application is an integrated component of the shell 11, the filter capacitor assembly 12, and the first external connector 14; the power module 2 is an integrated component of the power module, the heat sink assembly 22, the first signal connection terminal 23, and the third current-carrying component 24; the mainboard assembly 3 is an integrated component of the driver board, the integrated board 31 and the second plug-in core 32.

[0049] The power module 2, mainboard assembly 3 and integrated coreless current sensor AC assembly 4 in the motor controller of the present application are all riveted to the shell assembly 1 by screw riveting. The connection method is simple and easy to operate, and the riveting speed is fast, so batch riveting can be achieved, which effectively improves the assembly speed of the motor controller and improves the assembly efficiency.

[0050] Furthermore, the motor controller of the present application is divided into four large modules: a shell component 1, a power module 2, a mainboard component 3 and an integrated coreless current sensor AC component 4, so that the module-based production and assembly can improve the speed of production and assembly. In addition, the external interface position of each module is designed to be at a fixed position, and the structure of the shell component 1 and the integrated coreless current sensor AC component 4 remains unchanged in actual applications, so that the power module 2 and / or the structure of the integrated coreless current sensor AC component 4 can be replaced as needed, thereby realizing mass production of high-power motor controllers and low-power motor controllers as needed, so that the production of motor controllers has platformization, which can be adjusted according to actual needs and is flexible.

[0051] It should be noted that the present application does not impose any restrictions on the specific structure of the shell assembly 1. As long as the shell assembly 1 is an integrated part of a part of the device and can accommodate and assemble and fix the power module 2, the mainboard assembly 3 and the integrated coreless current sensor AC assembly 4, in actual applications, technical personnel in this field can set the specific structure of the shell assembly 1 according to actual needs.

[0052] In one embodiment, please refer to Figure 6 The housing assembly 1 includes a housing 11 , a filter capacitor assembly 12 and a potting resin 13 .

[0053] Among them, the shell 11 has a first accommodating cavity 101 and a second accommodating cavity 102 that are connected. The second accommodating cavity 102 is used to integrate a fixed filter capacitor assembly 12. The filter capacitor assembly 12 is located in the second accommodating cavity 102, and the potting resin 13 encapsulates the filter capacitor assembly 12 in the second accommodating cavity 102. The first end of the first current-carrying component 121 of the filter capacitor assembly 12 passes through the second accommodating cavity 102 and is electrically connected to the power module 2.

[0054] Please continue reading Figure 1 , Figure 3 and Figure 5 The power module 2, the mainboard assembly 3 and the integrated coreless current sensor AC assembly 4 are all riveted to the shell assembly 1. The mainboard assembly 3 is located on the side of the power module 2 away from the second accommodating cavity 102, the integrated coreless current sensor AC assembly 4 is arranged close to a side wall of the shell 11, and a part of the integrated coreless current sensor AC assembly 4 is located between the mainboard assembly 3 and the power module 2.

[0055] Such a setting, on the one hand, encapsulates the filter capacitor assembly 12 in the second accommodating cavity 102, which helps to ensure the stable operation of the filter capacitor assembly 12; on the other hand, the filter capacitor assembly 12, the power module 2, the integrated coreless current sensor AC assembly 4 and the mainboard assembly 3 are vertically stacked in sequence, and the shell 11 assembles the power module 2 and the integrated coreless current sensor AC assembly 4 upside down, which helps to minimize the volume of the motor controller, thereby improving the power density of the motor controller and making it more convenient to use.

[0056] In one embodiment, please also refer to Figure 2 and Figure 6 The housing 11 is provided with a first external connector 14, which includes a first connector housing 141 formed on the housing 11 and a first connector core 142 located in the first connector housing 141. The first connector core 142 includes a connector current-carrying member 1421, which is electrically connected to the second current-carrying member 122 of the filter capacitor assembly 12, and the second current-carrying member 122 is electrically connected to the first current-carrying member 121. The connector current-carrying member 1421 and part of the second current-carrying member 122 together form the first connector core 142.

[0057] The housing 11 is provided with a first external connector 14 , which is an external connection interface for connecting to a power source to provide a high-voltage direct current input for the motor controller.

[0058] In a preferred embodiment, the first plug-in housing 141 and the housing 11 are configured as an integral structure to facilitate manufacturing and reduce costs.

[0059] In one embodiment, please also refer to Figure 1 , Figure 2 and Figure 6 The shell 11 is provided with a water inlet 103 and a water outlet 104. By providing the water inlet 103 and the water outlet 104, it is convenient to install and route the water inlet and outlet pipes of the radiator assembly 22.

[0060] In one embodiment, the first current-carrying member 121 is a copper-aluminum composite bar. Setting the first current-carrying member 121 as a copper-aluminum composite bar can reduce the weight of the motor controller and reduce the cost. (Specifically, the upper and lower surfaces of the aluminum bar are copper layers, and the copper layer does not completely cover the aluminum bar).

[0061] In one embodiment, the plug-in current-carrying member 1421 is a copper-aluminum composite bar. Setting the plug-in current-carrying member 1421 as a copper-aluminum composite bar can reduce the weight of the motor controller and reduce the cost.

[0062] In one embodiment, the second current-carrying member 122 is a copper-aluminum composite bar. Setting the second current-carrying member 122 as a copper-aluminum composite bar can reduce the weight of the motor controller and reduce the cost.

[0063] In one embodiment, the plug-in current-carrying component 1421 and the second current-carrying component 122 are connected by ultrasonic welding.

[0064] In one embodiment, the first current carrying component 121 and the second current carrying component 122 are connected by soldering.

[0065] In one embodiment, please also refer to Figure 6 and Figure 1 The inner wall of the housing 11 is provided with a plurality of first rotary rivets 111, a plurality of second rotary rivets 112 and a plurality of third rotary rivets 113.

[0066] The power module 2 is provided with a first rivet hole 201 corresponding to the position of the first rivet 111 . The first rivet 111 is located in the first rivet hole 201 . After the first rivet 111 is riveted to the first rivet hole 201 , the power module 2 and the housing 11 can be fixed.

[0067] The integrated coreless current sensor AC component 4 is provided with a second rivet hole 401 corresponding to the position of the second rivet 112. The second rivet 112 is located in the second rivet hole 401. After the second rivet 112 is riveted to the second rivet hole 401, the integrated coreless current sensor AC component 4 can be fixed to the housing 11.

[0068] The mainboard assembly 3 is provided with a third rivet hole 301 corresponding to the position of the third rivet 113 . The third rivet 113 is located in the third rivet hole 301 . After the third rivet 113 is riveted to the third rivet hole 301 , the mainboard assembly 3 and the housing 11 can be fixed.

[0069] Through the above arrangement, the first rotary rivet 111, the second rotary rivet 112 and the third rotary rivet 113 are arranged on the inner wall of the shell 11 (i.e., the closed end side wall of the first accommodating cavity 101 close to the second accommodating cavity 102), and the first rotary rivet hole 201, the second rotary rivet hole 401 and the third rotary rivet hole 301 are respectively arranged on the power module 2, the integrated coreless current sensor AC component 4 and the mainboard component 3. The structure is simple, convenient for production and manufacturing, and has a good fixing effect, which is convenient for assembly and use.

[0070] In a preferred embodiment, the first rotary rivet 111 , the second rotary rivet 112 , and the third rotary rivet 113 are integrally formed with the housing 11 .

[0071] The first rotary rivet 111 , the second rotary rivet 112 , and the third rotary rivet 113 are provided with the housing 11 as an integral structure, which is convenient for production and manufacturing and has low cost.

[0072] In a preferred embodiment, the first rotary rivet 111, the second rotary rivet 112 and the third rotary rivet 113 all include a connected supporting portion and a riveting portion, the outer diameter of the riveting portion is smaller than the outer diameter of the supporting portion, and the outer diameter of the supporting portion is larger than the aperture of the corresponding rotary rivet hole, the riveting portion is used to dock with the rotary rivet hole for riveting, and can quickly position and assemble the riveted parts, the supporting portion is used to support the riveted parts so as to support the riveted parts to maintain a specific assembly height, and the riveted structure after riveting can limit the movement of the riveted parts along the axial direction of the rotary rivet, thereby improving the relative stability of the two riveted devices.

[0073] The heights of the supporting parts of the first rivet 111, the second rivet 112 and the third rivet 113 gradually increase. In the axial direction of the rivet, the position of the second rivet 112 after riveting with the second rivet hole 401 is between the position of the first rivet 111 after riveting with the first rivet hole 201 and the position of the third rivet 113 after riveting with the third rivet hole 301, so that the assembled power module 2, the integrated coreless current sensor AC component 4 and the mainboard component 3 are stacked in sequence, and a specific electrical gap is maintained between two adjacent components, which is more convenient to use and improves the safety performance of the motor controller.

[0074] It should be noted that the present application does not impose any restrictions on the specific number of the first spiral rivet 111, the second spiral rivet 112 and the third spiral rivet 113 and their respective setting positions, as long as the first spiral rivet 111, the second spiral rivet 112 and the third spiral rivet 113 are separated and distributed and do not affect each other. In practical applications, those skilled in the art can set the number and position of the first spiral rivet 111, the second spiral rivet 112 and the third spiral rivet 113 according to actual needs. For example, the number of the first spiral rivet 111 is four, and the four first spiral rivets 111 are respectively arranged along the four corners of the rectangle, corresponding to the four corners of the power module; the number of the second spiral rivet 112 is three, and the three second spiral rivets 112 are spaced apart; the number of the third spiral rivet 113 is four, and the four third spiral rivets 113 are respectively arranged along the four corners of the rectangle, corresponding to the four corners of the mainboard assembly 3. The adjustment and change of the number and position of the first rotary rivet 111, the second rotary rivet 112 and the third rotary rivet 113 do not deviate from the basic principles of the present application and should be limited within the protection scope of the present application.

[0075] In one embodiment, see Figure 1 , Figure 2 , Figure 3 and Figure 6 The housing 11 is also provided with a plurality of external connection holes 114. The external connection holes 114 are connection interfaces between the motor controller and the motor so as to install the motor controller on the motor.

[0076] Preferably, the power module 2 is provided with a first avoidance groove for the second rotary rivet 112 to pass through and a second avoidance groove for the third rotary rivet 113 to pass through. The power module is provided with a first avoidance groove and a second avoidance groove so that the second rotary rivet 112 and the third rotary rivet 113 can be smoothly docked and riveted with the integrated coreless current sensor AC component 4 and the mainboard component 3 for easy assembly.

[0077] It should be noted that the present application does not impose any restrictions on the specific structure of the mainboard assembly 3. In practical applications, those skilled in the art can set the specific structure of the mainboard assembly 3 according to actual needs. For example, the mainboard assembly 3 includes a connected drive board and a control board, or the mainboard assembly 3 includes an integrated board 31 of the drive board and the control board. And so on. Any adjustment and change to the structure of the mainboard assembly 3 does not deviate from the basic principles of the present application and should be limited within the scope of protection of the present application.

[0078] In one embodiment, please also refer to Figure 1 and Figure 2 The mainboard assembly 3 includes an integrated board 31 of a driving board and a control board, and a second plug-in core 32 is integrated on the integrated board 31. A second plug-in shell 151 is provided on the housing 11. The second plug-in core 32 and the second plug-in shell 151 together form a second external connector 15.

[0079] Through the above setting method, the mainboard assembly 3 is set as an integrated board 31 of the drive board and the control board, which can reduce the volume of the mainboard assembly 3, thereby helping to reduce the volume of the motor controller, and a second plug-in core 32 is integrated on the integrated board 31. The second plug-in core 32 and the second plug-in shell 151 of the shell 11 together form a second external connector 15. The second external connector 15 is the connection port of the mainboard assembly 3, which is used to power the mainboard assembly 3 and realize CAN communication connection between the motor controller and the vehicle control unit.

[0080] It should be noted that the present application does not impose any restrictions on the specific structure of the power module 2. In practical applications, those skilled in the art can set the specific structure of the power module 2 according to actual needs. For example, the power module 2 is a power module 2 that integrates a power module with a heat dissipation component, a signal connection terminal, and a current-carrying component. And so on. Any adjustment and change to the structure of the power module 2 does not deviate from the basic principles of the present application and should be limited within the scope of protection of the present application.

[0081] In one embodiment, please also refer to Figure 1 and Figure 5The power module 2 is an embedded PCBA power module in which an embedded PCBA power module 21 is deeply integrated with a heat sink assembly 22, a first signal connection terminal 23 and a third current-carrying component 24; the embedded PCBA power module 2 can be an embedded PCBA high-voltage power module or an embedded PCBA low-voltage power module, depending on whether the embedded PCBA power module 21 is a high-voltage power module or a low-voltage power module.

[0082] Among them, the embedded PCBA power module 21 is connected to the mainboard component 3 (specifically the integrated board 31 of the mainboard component 3) through the first signal connection terminal 23 (for example: crimping or welding), and the embedded PCBA power module 21 is connected to the first current carrier 121 and the integrated coreless current sensor AC component 4 through the third current carrier 24, specifically: the first end of the third current carrier 24 is connected to the first end of the first current carrier 121, and the second end of the third current carrier 24 is connected to the integrated coreless current sensor AC component 4.

[0083] Deeply integrating the heat sink assembly 22, the embedded PCBA power module 21, and the signal connection terminals and current connection terminals corresponding to the embedded PCBA power module 21 can reduce the volume of the power module 2, thereby further reducing the overall volume of the assembled motor controller, which helps to improve the power density of the motor controller.

[0084] Specifically, the radiator assembly 22 in the present application is a self-sealing radiator assembly, and the self-sealing radiator assembly can generally include: a self-sealing radiator assembly, an inlet and outlet water pipe, and a frame. The self-sealing radiator assembly has a first surface and a second surface that are relatively arranged. The self-sealing radiator assembly itself has a complete heat dissipation waterway, which is itself a whole and does not require subsequent assembly. The inlet and outlet water pipes are connected to the first surface of the self-sealing radiator assembly, such as the lower surface of the self-sealing radiator assembly. The inlet and outlet water pipes provide an external interface for the heat dissipation waterway for the embedded PCBA power module 2. The frame is connected to the second surface of the self-sealing radiator assembly, such as the upper surface of the self-sealing radiator assembly. Among them, the frame and the second surface of the self-sealing radiator assembly form a cavity to install the embedded PCBA power module 21. In specific implementation, the inlet and outlet water pipes, the self-sealing radiator assembly and the frame can be connected into a whole by integrated brazing. Compared with the traditional assembled heat dissipation waterway, the size and space are greatly reduced, and there is a low risk of coolant leakage.

[0085] In addition, in other embodiments, the self-sealing radiator assembly may also include: a self-sealing radiator assembly and an inlet and outlet water pipe. The self-sealing radiator assembly may also be in other forms, as long as it can meet the functions of the embedded PCBA power module 2, and can be flexibly configured according to requirements.

[0086] In one embodiment, see Figure 1 The power module 2 further includes a positioning support column 202 disposed on the embedded PCBA power module 21, and the positioning support column 202 is disposed toward the mainboard assembly 3 and abuts against the mainboard assembly 3. By providing the positioning support column 202, the mainboard assembly 3 can be supported from multiple positions, so that a specific electrical gap is maintained between the power module 2 and the mainboard assembly 3, which helps to ensure safety.

[0087] Preferably, the third current-carrying member 24 is a copper-aluminum composite bar. Setting the third current-carrying member 24 as a copper-aluminum composite bar can reduce the weight of the motor controller and reduce the cost.

[0088] In one embodiment, the first end of the third current carrying member 24 is laser welded to the first end of the first current carrying member 121 .

[0089] It should be noted that the present application does not impose any restrictions on the specific structure of the integrated coreless current sensor AC component 4. In practical applications, those skilled in the art can set the specific structure of the integrated coreless current sensor AC component 4 according to actual needs. Any adjustment and change to the specific structure of the integrated coreless current sensor AC component 4 does not deviate from the basic principles of the present application and should be limited to the protection scope of the present application.

[0090] In one embodiment, please participate in Figure 1 and Figure 5 The integrated coreless current sensor AC component 4 is partially potted as one by three groups of output components 41, and an external sealing interface 403 and an AC output port 402 are formed at the output end of each group of output components 41. The external sealing interface 403 is a sealing interface between the motor controller and the motor cavity, and the connection is kept sealed after the motor and the motor controller are assembled, and the AC output port 402 is an interface for connecting the AC and the motor.

[0091] Among them, each group of output components 41 includes a coreless current sensor 411 and a fourth current carrier 412, the coreless current sensor 411 is electrically connected to the fourth current carrier 412, and the coreless current sensor 411 is connected to the mainboard component 3 through the second signal connection terminal 413 (for example: crimping or welding), the first end of the fourth current carrier 412 is electrically connected to the power module 2 (specifically the second end of the third current carrier 24), the second end of the fourth current carrier 412 passes through the external sealing structure to form an AC output port 402, and the three AC output ports 402 are spaced apart in a straight line direction.

[0092] The above setting method uses resin to encapsulate the three groups of output components 41 into one, which is convenient for assembling and connecting the three groups of output components 41 at the same time, helps to improve assembly efficiency, and at the same time arranges the three groups of output components 41 in an orderly manner, which helps to reduce the volume of the assembled motor controller, thereby increasing the power density.

[0093] In one embodiment, the fourth current-carrying member 412 is a copper-aluminum composite bar. Setting the fourth current-carrying member 412 as a copper-aluminum composite bar can reduce the weight of the motor controller and reduce the cost.

[0094] In one embodiment, the first end of the fourth current carrying member 412 is laser welded to the second end of the third current carrying member 24 .

[0095] The motor controller shown in the present application is assembled with the housing assembly 1 as the base. After the housing assembly 1 is inverted, the power module 2, the integrated coreless current sensor AC assembly 4, and the mainboard assembly 3 are assembled in sequence. The specific assembly process is as follows:

[0096] (1) The housing assembly 1 is turned upside down, the power module 2 is placed in the first accommodating cavity 101, and the first end of the third current-carrying component 24 of the power module 2 is connected to the first end of the first current-carrying component 121. Then, a plurality of first rivets 111 are simultaneously riveted to their corresponding first rivet holes 201 by a riveting machine, thereby fixing the power module 2 to the housing assembly 1.

[0097] (2) The integrated coreless current sensor AC component 4 is placed in the first accommodating cavity 101, and the second rivet 112 is inserted into the second rivet hole 401, and the first end of the fourth current-carrying component 412 of the integrated coreless current sensor AC component 4 is connected to the second end of the third current-carrying component 24 of the power module 2. Then, a plurality of second rivets 112 are simultaneously riveted to their corresponding second rivet holes 401 by a rivet machine, so as to fix the integrated coreless current sensor AC component 4 to the housing component 1.

[0098] (3) Place the mainboard assembly 3 into the first accommodating cavity 101, and insert the third rivet 113 into the third rivet hole 301, and respectively connect the second signal connection terminal 413 of the integrated coreless current sensor AC assembly 4 and the first signal connection terminal 23 of the power module 2 to the integrated board 31 of the mainboard assembly 3, and then rivet multiple third rivets 113 to their corresponding third rivet holes 301 simultaneously by a rivet machine, so as to fix the mainboard assembly 3 and the shell assembly 1, and then assemble them into a complete motor controller.

[0099] The positive and negative paths of the DC of the motor controller of the present application are specifically: the first external connector 14 (plug-in current carrier 1421→second current carrier 122)→filter capacitor assembly 12→first current carrier 121→third current carrier 24→power module 2→third current carrier 24→first current carrier 121→filter capacitor assembly 12→first external connector 14 (second current carrier 122→plug-in current carrier 1421).

[0100] The DC to AC conversion path of the motor controller of the present application is specifically: first external connector 14 (connector current carrier 1421 → second current carrier 122) → filter capacitor component 12 → first current carrier 121 → third current carrier 24 → power module 2 → third current carrier 24 → fourth current carrier 412 → integrated coreless current sensor AC component 4 → AC output port 402 of the fourth current carrier 412.

[0101] So far, the technical solutions of the present application have been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it is easy for those skilled in the art to understand that the protection scope of the present application is obviously not limited to these specific embodiments. Without departing from the principles of the present application, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will fall within the protection scope of the present application.

Claims

1. A motor controller, characterized in that: Including housing assembly, power module, mainboard assembly and integrated coreless current sensor AC assembly, The housing assembly has a first accommodating cavity, the power module and the mainboard assembly are located in the first accommodating cavity, a portion of the integrated coreless current sensor AC assembly is located in the first accommodating cavity, and another portion extends out of the first accommodating cavity to form an AC output port. The power module, the mainboard assembly and the integrated coreless current sensor AC assembly are all riveted to the shell assembly.

2. The motor controller according to claim 1, characterized in that: The housing assembly comprises a housing, a filter capacitor assembly and a potting resin. The housing has the first accommodating cavity and the second accommodating cavity connected to each other, the filter capacitor assembly is located in the second accommodating cavity, and the potting resin encapsulates the filter capacitor assembly in the second accommodating cavity, and the first end of the first current-carrying member of the filter capacitor assembly passes through the second accommodating cavity and is electrically connected to the power module; The power module, the mainboard assembly and the integrated coreless current sensor AC assembly are all riveted to the shell assembly. The mainboard assembly is located on a side of the power module away from the second accommodating cavity, the integrated coreless current sensor AC assembly is arranged close to a side wall of the shell, and a part of the integrated coreless current sensor AC assembly is located between the mainboard assembly and the power module.

3. The motor controller according to claim 2, characterized in that: The housing is provided with a first external connector, the first external connector comprises a first connector housing formed on the housing and a first connector core located in the first connector housing, the first connector core comprises a connector current-carrying member, the connector current-carrying member is electrically connected to a second current-carrying member of the filter capacitor assembly, and the second current-carrying member is electrically connected to the first current-carrying member; And / or, the shell is provided with a water inlet and a water outlet.

4. The motor controller according to claim 3, characterized in that: The first current-carrying component is a copper-aluminum composite bar; And / or, the plug-in current-carrying component is a copper-aluminum composite bar; And / or, the second current-carrying component is a copper-aluminum composite bar.

5. The motor controller according to claim 2, characterized in that: The inner side wall of the shell is provided with a plurality of first rotary rivets, a plurality of second rotary rivets and a plurality of third rotary rivets. The power module is provided with a first rotary rivet hole corresponding to the position of the first rotary rivet, the first rotary rivet is located in the first rotary rivet hole, and the power module and the housing can be fixed after the first rotary rivet is riveted to the first rotary rivet hole; The integrated coreless current sensor AC component is provided with a second rivet hole corresponding to the position of the second rivet, the second rivet is located in the second rivet hole, and the integrated coreless current sensor AC component can be fixed to the housing after the second rivet is riveted to the second rivet hole; The mainboard assembly is provided with a third rivet hole corresponding to the position of the third rivet. The third rivet is located in the third rivet hole. After the third rivet is riveted with the third rivet hole, the mainboard assembly and the shell can be fixed.

6. The motor controller according to claim 5, characterized in that: The first rotary rivet, the second rotary rivet and the third rotary rivet all include a supporting portion and a riveting portion connected to each other, the outer diameter of the riveting portion is smaller than the outer diameter of the supporting portion, and the outer diameter of the supporting portion is larger than the hole diameter of the corresponding rotary rivet hole, the heights of the supporting portion of the first rotary rivet, the supporting portion of the second rotary rivet and the supporting portion of the third rotary rivet gradually increase, and in the axial direction of the rotary rivet, the position after the second rotary rivet is riveted with the second rotary rivet hole is between the position after the first rotary rivet is riveted with the first rotary rivet hole and the position after the third rotary rivet is riveted with the third rotary rivet hole.

7. The motor controller according to claim 6, characterized in that: The power module is provided with a first avoidance groove for the second rotary rivet to pass through and a second avoidance groove for the third rotary rivet to pass through; And / or, the first rotary rivet, the second rotary rivet and the third rotary rivet are an integral structure with the shell.

8. The motor controller according to any one of claims 1 to 7, characterized in that: The mainboard assembly includes an integrated board of a driving board and a control board, and a second plug-in core is integrated on the integrated board. A second plug-in shell is provided on the shell, and the second plug-in core and the second plug-in shell together form a second external connector.

9. The motor controller according to any one of claims 2 to 7, characterized in that: The power module is an embedded PCBA power module in which an embedded PCBA power module is deeply integrated with a heat sink assembly, a first signal connection terminal and a third current-carrying component; The embedded PCBA power module is connected to the mainboard assembly through the first signal connection terminal, and the embedded PCBA power module is respectively connected to the first end of the first current-carrying component and the integrated coreless current sensor AC component through the third current-carrying component; And / or, the integrated coreless current sensor AC component is partially potted as one by three groups of output components, and an external sealing interface and an AC output port are formed at the output end of each group of output components, each group of output components includes a coreless current sensor and a fourth current carrier, the coreless current sensor is electrically connected to the fourth current carrier, the coreless current sensor is connected to the mainboard component through a second signal connection terminal, the first end of the fourth current carrier is electrically connected to the power module, the second end of the fourth current carrier passes through the external sealing structure to form the AC output port, and the three AC output ports are spaced apart in a straight line direction.

10. The motor controller according to claim 9, characterized in that: The third current-carrying component is a copper-aluminum composite bar; And / or, the fourth current-carrying component is a copper-aluminum composite bar.

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