Support capacitor and dual-motor controller

Abstract

The invention discloses a support capacitor and a dual-motor controller, and relates to the technical field of dual-motor controllers. Wherein the supporting capacitor comprises a capacitor shell, a positive electrode copper bar, an insulating layer, a capacitor core body, a negative electrode copper bar and an insulating layer which are sequentially stacked from bottom to top; the dual-motor controller is composed of a supporting capacitor and a parallel tube IGBT module, the parallel tube IGBT module is composed of a plurality of parallel tube IGBT assemblies, each parallel tube IGBT assembly is formed by connecting a plurality of IGBTs in parallel and welding the IGBTs through an IGBT driving plate, each parallel tube IGBT assembly further comprises a copper busbar, and each IGBT is connected with the copper busbar through a screw; the capacitor core body is connected to the IGBT through a positive electrode copper bar and a negative electrode copper bar which support the two sides of the capacitor. According to the embodiment of the invention, the supporting capacitors are redesigned, and the IGBTs are used in parallel, so that the problems that the number of parts is large, the assembly is complex, and the size is large are solved.

Description

Technical Field

[0001] The present application belongs to the technical field of dual-motor controllers, and in particular, relates to a support capacitor and a dual-motor controller. Background Art

[0002] As the power demand for electric drive systems of vehicles, especially new energy heavy trucks, increases and the volume demand decreases, the current single-motor system (single motor + single motor controller) can hardly meet the needs of vehicles. Vehicles are gradually moving towards dual-motor solutions such as electric drive bridges and dual-motor systems. In this process, the motor controller also needs to be upgraded from the original single-motor controller to a dual-motor controller. Even if the vehicle is changed to dual motors, the power of each motor is relatively large, and IGBTs need to be paralleled to increase their driving capabilities (a single IGBT can hardly meet the motor power requirements due to limited heat dissipation capacity).

[0003] The main route in the industry at present is to use two independent IGBT parallel-tube motor controllers to drive two motors respectively, or simply place two independent motor controllers in a larger housing for integration to facilitate vehicle layout, etc., as shown in patent CN218104003U. Or develop a single IGBT with stronger driving and heat dissipation capabilities.

[0004] If two independent motor controllers are used for high-power dual-motor control, the layout of the whole vehicle will be difficult, the assembly will be troublesome, and the material cost will be high. If two independent motor controllers are used or simply placed in a larger housing for integration, although the layout and assembly problems of the whole vehicle can be improved a little, the problems of large size, high integration cost and high cost are still prominent. The newly developed single IGBT with greater driving capability and stronger heat dissipation capability requires a lot of R&D cost and verification cycle, which is difficult to quickly commercialize in the commercial vehicle field. Summary of the invention

[0005] The purpose of this application is to provide a support capacitor and a dual-motor controller, which solves the problems of large number of parts, complex assembly and large size by redesigning the support capacitor and using IGBT in parallel.

[0006] In order to achieve the above objectives, the solution of this application is: In a first aspect, an embodiment of the present application provides a support capacitor, comprising a capacitor housing, a positive copper busbar, an insulating layer, a capacitor core, a negative copper busbar, and an insulating layer stacked in sequence from bottom to top; The capacitor shell is the external packaging of the supporting capacitor, which is used to fix and protect the supporting capacitor; the positive copper bar is the positive conductive part of the supporting capacitor, which is used to transmit positive charge; the capacitor core is composed of multiple small capacitor cores, and the multiple small capacitor cores are combined in parallel or in series; the negative copper bar is the negative conductive part of the supporting capacitor, which is used to transmit negative charge; the positive copper bar and the negative copper bar form a cavity inside the capacitor shell to arrange the capacitor core, and the copper bars of the positive copper bar and the negative copper bar are both provided with openings, and the capacitor core is welded through the openings on the positive copper bar and the negative copper bar to achieve electrical connection; the insulating layer is used to provide electrical isolation for the supporting capacitor.

[0007] According to the above method of the embodiment of the present application, the following additional technical features may also be provided: Furthermore, a positive input copper bar is welded to the outside of the positive copper bar, which is connected to the positive pole of an external power supply through the positive input copper bar. A negative input copper bar is welded to the outside of the negative copper bar, which is connected to the negative pole of an external power supply through the negative input copper bar. The positive copper bar and the negative copper bar are stacked to lead the positive and negative power supplies to both sides of the capacitor core.

[0008] Furthermore, the positive input copper bar and the negative input copper bar are arranged up and down, including the positive input copper bar above the negative input copper bar or the positive input copper bar below the negative input copper bar.

[0009] In the second aspect, an embodiment of the present application provides a dual-motor controller, which is composed of the supporting capacitor and the parallel-tube IGBT module of the first aspect, wherein the parallel-tube IGBT module is composed of multiple parallel-tube IGBT components, the parallel-tube IGBT component is composed of multiple IGBTs connected in parallel and welded through an IGBT driving board, and the parallel-tube IGBT component also includes a bus bar, and each IGBT is connected to the bus bar by a screw; the capacitor core is connected to the IGBT through the positive copper bus and the negative copper bus on both sides of the supporting capacitor.

[0010] Compared with the prior art, the support capacitor and the dual-motor controller provided in the embodiments of the present application have the following beneficial technical effects: The embodiment of the present application makes the structure of the supporting capacitor more compact and effectively utilizes the space through the design of the capacitor housing, positive copper busbar, insulating layer, capacitor core, negative copper busbar and insulating layer stacked in sequence from bottom to top, while ensuring the high performance of the capacitor. The positive copper busbar and the negative copper busbar lead the positive and negative power sources to the two sides of the capacitor core in a stacked manner, thereby improving the charge transfer efficiency; the capacitor core is electrically connected by welding through the openings on the positive copper busbar and the negative copper busbar. This welding method ensures the stability and reliability of the electrical connection, reduces resistance and inductance, and improves the charging and discharging efficiency of the capacitor; the setting of the positive input copper busbar and the negative input copper busbar makes the connection with the external power supply more convenient, and the number of capacitor cores can be increased or decreased as needed to meet different capacitor requirements.

[0011] The dual-motor controller composed of a supporting capacitor and a parallel-tube IGBT module in the embodiment of the present application has high-performance control capabilities. The parallel-tube IGBT module is composed of multiple parallel-tube IGBT components, each of which is composed of multiple IGBTs in parallel and welded together through an IGBT drive board. This design improves the current carrying capacity and switching speed of the controller, allowing the controller to more accurately control the operation of the motor; since the IGBT component is connected to the bus bar by screws, this connection method not only ensures the stability of the electrical connection, but also contributes to heat dissipation. The bus bar has good thermal conductivity, which can quickly conduct the heat generated by the IGBT, reduce the operating temperature of the IGBT, and improve the reliability and service life of the controller; the dual-motor controller has a high degree of integration and a compact structure, which reduces the occupied space and reduces the cost.

[0012] The embodiment of the present application redesigns the supporting capacitor and uses the IGBT in parallel to enhance its driving capability, arranges it on both sides of the capacitor, and connects it through the laminated busbars led out from both sides of the capacitor, thereby driving two high-power motors and integrating two motor controllers. When two high-power motors need to be driven, there is no need to use two independent motor controllers or two independent motor controllers in one housing, which can simplify the layout of the entire vehicle, reduce the number of positive and negative connectors of the entire vehicle, the number of high-voltage cables, etc., reduce the difficulty of assembling the entire vehicle, and greatly save the space of the entire vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 The overall schematic diagram of the structure of the support capacitor according to the embodiment of the present application is shown; Figure 2 A schematic diagram of an exploded structure of a support capacitor according to an embodiment of the present application is shown; Figure 3 The overall schematic diagram of the structure of the support capacitor of another embodiment of the present application is shown; Figure 4 A schematic diagram of an exploded structure of a support capacitor according to another embodiment of the present application is shown; Figure 5 The overall schematic diagram of the dual motor controller according to the embodiment of the present application is shown; Figure 6 The overall schematic diagram of the structure of the parallel-tube IGBT assembly of the embodiment of the present application is shown; Figure 7 A schematic cross-sectional view of the structure of a dual-motor controller according to an embodiment of the present application is shown; Figure 8 A partial enlarged schematic diagram of a dual-motor controller according to an embodiment of the present application is shown; Fig. 9A schematic diagram of the overall structure of a parallel-tube IGBT assembly according to another embodiment of the present application is shown.

[0014] Explanation of the reference numerals: 10, supporting capacitor; 20, parallel-tube IGBT assembly; 30, connecting screws between supporting capacitor and IGBT; 11, capacitor housing; 12, positive copper busbar; 12-1 / 12-2, positive input copper busbar; 14, capacitor core; 15, negative copper busbar; 15-1 / 15-2, negative input copper busbar; 21, IGBT; 23, screws; 22 / 26 / 22a~22f, busbar; 24 / 25, IGBT drive board; 13 / 16 / 17 / 18, insulating layer. DETAILED DESCRIPTION

[0015] In order to make the above-mentioned purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are described in detail below in conjunction with the accompanying drawings. It is to be understood that the specific embodiments described herein are only used to explain the present application, rather than to limit the present application. It should also be noted that, for ease of description, only some structures related to the present application are shown in the accompanying drawings, rather than all structures. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application.

[0016] The terms "including" and "having" and any variations thereof in this application are intended to cover non-exclusive inclusions. For example, a process, method, system, product or device comprising a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products or devices.

[0017] Reference to "embodiments" in this application means that a particular feature, structure, or characteristic described in conjunction with the embodiments may be included in at least one embodiment of the present application. The appearance of the phrase in various locations in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment that is mutually exclusive with other embodiments. It is explicitly and implicitly understood by those skilled in the art that the embodiments described in this application may be combined with other embodiments.

[0018] like Figure 1 and Figure 2 As shown, the embodiment of the present application provides a support capacitor 10, wherein: Figure 1 This is a schematic diagram of the overall structure of the supporting capacitor according to the embodiment of the present application. Figure 2 This is an exploded schematic diagram of the structure of the supporting capacitor of the embodiment of the present application, including a capacitor housing 11, a positive copper busbar 12, insulating layers 13, 18, a capacitor core 14, a negative copper busbar 15 and insulating layers 16, 17 stacked in sequence from bottom to top.

[0019] Specifically, the capacitor housing 11 serves as an external package for the supporting capacitor 10. The capacitor housing 11 serves to fix and protect the supporting capacitor 10, thereby ensuring the stability and safety of the internal structure of the capacitor. Figure 1 The circled area on the middle capacitor shell 11 is the capacitor fixing point; the positive copper bar 12 serves as the positive conductive part of the supporting capacitor 10, and the positive copper bar 12 is responsible for transmitting positive charges. It is connected to the positive electrode of the capacitor core 14, ensuring the effective transmission of charges; the negative copper bar 15 serves as the negative conductive part of the supporting capacitor 10, and the negative copper bar 15 is responsible for transmitting negative charges. It is connected to the negative electrode of the capacitor core 14, also ensuring the effective transmission of charges; the positive copper bar 12 and the negative copper bar 15 form a cavity inside the capacitor shell 11, and this cavity is used to arrange the capacitor core 14. Such a design not only saves space, but also improves the integration and stability of the capacitor.

[0020] The capacitor core 14 is the core part of the supporting capacitor 10, which is composed of a plurality of small capacitor cores, which can be combined in parallel or in series to meet different capacitor requirements. By adjusting the number and connection method of the small cores, the capacity and performance of the capacitor can be flexibly adjusted.

[0021] The insulating layer is used to provide electrical isolation for the supporting capacitor 10, thereby ensuring the electrical safety of the internal structure of the capacitor and preventing problems such as charge leakage and short circuit.

[0022] A positive input copper bar 12-1 is welded on the outside of the positive copper bar 12, and is connected to the positive pole of the external power supply through the positive input copper bar 12-1. Similarly, a negative input copper bar 15-1 is welded on the outside of the negative copper bar 15, and is connected to the negative pole of the external power supply through the negative input copper bar 15-1. Such a design enables the support capacitor 10 to be easily connected and disconnected with the external power supply; the positive copper bar 12 and the negative copper bar 15 lead the positive and negative power supplies to both sides of the capacitor core 14 in a laminated manner. Such a layout not only saves space, but also improves the efficiency and stability of power transmission.

[0023] The positive input copper bar and the negative input copper bar can be arranged up and down, including the positive input copper bar above the negative input copper bar or the positive input copper bar below the negative input copper bar. Figure 3 and Figure 4 As shown, Figure 3 This is a schematic diagram of the overall structure of the support capacitor 10 according to another embodiment of the present application. Figure 4 FIG. 1 is a schematic diagram of an exploded structure of a supporting capacitor 10 according to another embodiment of the present invention. Figure 1 and Figure 2 The difference between the supporting capacitor 10 shown is that Figure 1 and Figure 2In the embodiment shown, the positive input copper bar 12-1 is above the negative input copper bar 15-1. Figure 3 and Figure 4 In the illustrated embodiment, the positive input copper busbar 12 - 2 is below the negative input copper busbar 15 - 2 . Such a design provides more layout flexibility and can be adjusted according to actual application scenarios and needs.

[0024] like Figure 5 As shown, an embodiment of the present application provides a dual-motor controller, which is composed of the above-mentioned support capacitor 10 and a parallel-tube IGBT module, wherein the support capacitor 10 includes core parts such as a capacitor housing 11, a positive copper busbar 12, insulating layers 13, 16, 17, 18, a capacitor core 14, and a negative copper busbar 15. The design of the support capacitor 10 is intended to provide stable power storage and transmission to ensure that the motor controller can work efficiently and reliably.

[0025] The parallel IGBT module is another important component of the dual motor controller, which is composed of multiple parallel IGBT components 20. Figure 6 As shown, each component includes a plurality of IGBTs 21, and these devices are welded together through an IGBT driving board 24. This design not only improves the current handling capability, but also enhances the reliability and stability of the system.

[0026] Specifically, the parallel IGBT modules on both sides of this embodiment are composed of three IGBTs 21 on each side, each IGBT 21 corresponds to a bus copper bar 22a, 22b, 22c, 22d, 22e, 22f, and are connected to the support capacitor 10 through the support capacitor and IGBT connecting screws 30.

[0027] The parallel IGBT assembly 20 of the embodiment of the present application improves the current carrying capacity by connecting multiple IGBTs 21 in parallel. This design enables the controller to handle larger loads while maintaining efficient energy conversion. Each IGBT 21 is connected to the busbar 22 by screws 23, which helps to evenly distribute the current and dissipate heat. The use of the busbar 22 further enhances the electrical performance and thermal management capabilities of the controller; the IGBT driver board 24 is connected to the IGBT 21 by welding. This connection method ensures stable signal transmission and firm fixation of the assembly.

[0028] Specifically, Figure 7 and Figure 8 As shown, Figure 7 : is a schematic cross-sectional view of the structure of the dual-motor controller according to an embodiment of the present application, Figure 8It is a partial enlarged schematic diagram of the dual motor controller of the embodiment of the present application. A positive copper bar 12 and a negative copper bar 15 on each side of the supporting capacitor 10 are led out and connected to the IGBT21 by means of lamination. The positive and negative copper bars 15 are insulated and isolated by insulating layers 13, 16, 17, and 18. The negative copper bar 15 is isolated from the external device by insulating layers 16 and 17 to prevent possible high-voltage breakdown from causing insulation abnormalities. The cavity between the positive copper bar 12 and the negative copper bar 15 is arranged with a capacitor core 14, wherein the lamination on one side is, from outside to inside, an insulating layer 16, a negative copper bar 15, an insulating layer 13, and a positive copper bar 12, and the innermost side is a capacitor housing 11. The lamination sequence on the other side is consistent, and will not be repeated here.

[0029] After the welding of the positive and negative copper busbars 15, the capacitor core 14, the insulating layers 13, 16, 17, 18, etc. is completed, the embodiment of the present application is placed in the capacitor housing 11 and finally epoxy resin potting is performed to obtain the dual-motor controller of this embodiment. It should be noted that the schematic diagrams of the supporting capacitor 10 of the embodiment of the present application do not show potting.

[0030] In addition, if Figure 6 As shown in FIG. 1 , it can be seen that the parallel IGBT assembly 20 of the embodiment of the present application is composed of two IGBTs 21 connected in parallel. In another embodiment, as shown in FIG. Fig. 9 As shown, a parallel IGBT assembly consisting of three IGBTs 21 connected in parallel is also provided. The embodiment of the present application does not limit the number of IGBTs in the parallel IGBT assembly. It is only necessary to make adaptive changes to the IGBT driver board 25, the busbar 26 and the support capacitor 10 to adapt to achieve a higher power output. It should be noted that the packaging form of the parallel IGBT assembly 20 shown in the drawings of the embodiment of the present application is only used to illustrate the connection relationship between the various components, and different packaging forms are within the protection scope of the embodiment of the present application.

[0031] The embodiments of the present application are described above in conjunction with the accompanying drawings, but the present application is not limited to the above-mentioned specific implementation methods. The above-mentioned specific implementation methods are merely illustrative and not restrictive. Under the guidance of the present application, ordinary technicians in this field can also make many forms without departing from the purpose of the present application and the scope of protection of the claims, all of which are within the protection of the present application.

Claims

1. A support capacitor, characterized in that: The supporting capacitor (10) comprises a capacitor housing (11), a positive copper busbar (12), insulating layers (13, 18), a capacitor core (14), a negative copper busbar (15) and insulating layers (16, 17) which are stacked in sequence from bottom to top; The capacitor housing (11) is an external package of the support capacitor (10) and is used to fix and protect the support capacitor (10); the positive copper bar (12) is the positive conductive part of the support capacitor (10) and is used to transmit positive charges; the capacitor core (14) is composed of a plurality of small capacitor cores, and the plurality of small capacitor cores are combined in parallel or in series; the negative copper bar (15) is the negative conductive part of the support capacitor (10) and is used to transmit negative charges; the positive copper bar (12) and the negative copper bar (15) form a cavity inside the capacitor housing (11) for arranging the capacitor core (14); the copper bars of the positive copper bar (12) and the negative copper bar (15) are both provided with openings, and the capacitor core (14) is welded through the openings on the positive copper bar (12) and the negative copper bar (15) to achieve electrical connection; and the insulating layer is used to provide electrical isolation for the support capacitor (10).

2. The support capacitor according to claim 1, characterized in that: A positive input copper bar (12-1) is welded to the outside of the positive copper bar (12), and the positive input copper bar (12-1) is connected to the positive electrode of an external power source. A negative input copper bar (15-1) is welded to the outside of the negative copper bar (15), and the negative input copper bar (15-1) is connected to the negative electrode of an external power source. The positive copper bar (12) and the negative copper bar (15) are stacked to lead the positive and negative power sources to both sides of the capacitor core (14).

3. The support capacitor according to claim 2, characterized in that: The positive electrode input copper bar (12-1) and the negative electrode input copper bar (15-1) are arranged up and down, including the positive electrode input copper bar (12-1) above the negative electrode input copper bar (15-1) or the positive electrode input copper bar (12-2) below the negative electrode input copper bar (15-2).

4. A dual motor controller, characterized in that: The dual-motor controller comprises a support capacitor (10) and a parallel IGBT module as claimed in any one of claims 1 to 3, wherein the parallel IGBT module comprises a plurality of parallel IGBT components (20), the parallel IGBT component (20) comprises a plurality of IGBTs (21) connected in parallel and welded together via an IGBT drive plate (24), the parallel IGBT component (20) further comprises a busbar (22), each IGBT (21) being connected to the busbar (22) via a screw (23); the capacitor core (14) is connected to the IGBT (21) via a positive copper busbar (12) and a negative copper busbar (15) on both sides of the support capacitor (10).

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