Integrated four-motor controller

Abstract

An integrated four-motor controller disclosed by the present invention comprises a case with a heat conduction effect and a control module arranged in the case, the control module comprises a control panel, a bus capacitor and four motor driving boards, the bus capacitor is installed in an inner cavity of the case, the control panel is installed above the bus capacitor, and the four motor driving boards are installed on the control panel. The two sides of the bus capacitor are each provided with two motor driving boards, one side of each motor driving board is electrically connected with the bus capacitor, the other side of each motor driving board is electrically connected with a motor three-phase line interface, and the lower surface of the case is provided with a cooling liquid flow channel. The four motor driving boards, the control board and the bus capacitor share one case to form an integrated structure, and compared with a discrete controller, the total size of the controller is reduced, the cost is effectively reduced, and light-weight, small-size and low-cost development of an automobile is facilitated; and meanwhile, the integrated controller reduces external wiring between discrete control, fault points are reduced, the size and the cost are saved, and the reliability of the product is improved at the same time.

Description

Technical Field

[0001] The present invention relates to the technical field of motor controllers, and more specifically, to an integrated four-motor controller. Background Art

[0002] With the further development of electric vehicle technology, the demand for new energy electric vehicles is increasing, and the demand for new energy technology in the heavy-duty truck field is also increasing.

[0003] At present, the electronic control of heavy trucks on the market is generally in the form of single electronic control, that is, the motor and the motor controller are one-to-one. This method causes a lot of duplication of components, chips and functional circuits, makes the hardware system complicated, and is not convenient for wiring harness layout. The entire control unit is large in size and weight, resulting in complex control systems, low reliability, increased costs, low space utilization, and inconvenient debugging and maintenance. In addition, since each motor controller is independent of each other, it has high requirements for synchronous control and it is difficult to ensure the coordination of the motors.

[0004] Therefore, it is necessary to propose a new solution to solve the above problems. Summary of the invention

[0005] The purpose of the present invention is to overcome the deficiencies of the above-mentioned prior art and to provide an integrated four-motor controller. Four motor drive boards, a control board and bus capacitors share a chassis to form an integrated structure. Compared with discrete controllers, the total volume of the controller is reduced, and the cost is effectively reduced. At the same time, the integrated controller reduces the external wiring between discrete controls and reduces the failure points. While saving volume and cost, it improves the reliability of the product.

[0006] In order to achieve the above object, the present invention adopts the following technical solution:

[0007] An integrated four-motor controller includes a chassis with a heat-conducting effect and a control module arranged in the chassis, wherein the control module includes a control board, a bus capacitor, and four motor drive boards, the bus capacitor is installed in the inner cavity of the chassis, the control board is installed above the bus capacitor, two motor drive boards are arranged on both sides of the bus capacitor, one side of the motor drive board is electrically connected to the bus capacitor, and the other side of the motor drive board is electrically connected to the motor three-phase line interface, one end of the bus capacitor is electrically connected to a single-hole through-hole connector, and a coolant flow channel is provided on the lower surface of the chassis, and the bus capacitor and the four motor drive boards are cooled by passing coolant.

[0008] Furthermore, the coolant flow channel includes coolant flow channel one, coolant flow channel two and coolant flow channel three, and the coolant flow channel one, coolant flow channel two and coolant flow channel three are connected to form an S-shaped structure, and the coolant flow channel one and coolant flow channel three are provided with a receiving groove recessed in the coolant flow channel at the position corresponding to the motor drive plate, and the receiving groove is provided with a plurality of convex columns distributed in an array, and the convex columns are perpendicular to the coolant flow channel, and the coolant flow channel two is provided with a plurality of convex ridges parallel to and integrated with the chassis at the position corresponding to the bus capacitor, and the convex ridges are arranged along the flow direction of the coolant in the coolant flow channel two.

[0009] Furthermore, the channel diameter at the connection between coolant channel one and coolant channel two is smaller than the channel diameters of coolant channel one and coolant channel two, and the channel diameter at the connection between coolant channel three and coolant channel two is smaller than the channel diameters of coolant channel three and coolant channel two.

[0010] Furthermore, the free end of the coolant channel 1 and the free end of the coolant channel 3 are both connected to a coolant interface, and the two coolant interfaces extend outside the open end of the chassis.

[0011] Furthermore, the control board is installed with a signal maintenance plug-in, a low voltage plug-in, and four resolver plug-ins electrically connected thereto.

[0012] Furthermore, an isolation plate is installed on the upper surface of the bus capacitor, and the control board is installed on the upper surface of the isolation plate.

[0013] Furthermore, a chassis cover is installed at the open end of the chassis, and the chassis cover is provided with a single-hole through-hole connector hole, a coolant interface hole, a signal maintenance plug-in hole, and a low-voltage plug-in hole.

[0014] Furthermore, a motor three-phase line interface hole and a resolver outlet hole are provided on both sides of the chassis, the motor three-phase line interface hole corresponds to the motor three-phase line interface, and the resolver outlet hole is located between the two motor three-phase line interface holes.

[0015] Furthermore, a chassis back plate for sealing the coolant flow channel is installed on the lower surface of the chassis.

[0016] Furthermore, the integrated four-motor controller has a square structure with dimensions of: length 536mm*width 536mm*height 249mm.

[0017] The beneficial effects of the present invention are:

[0018] 1. In the present invention, a design is adopted in which four motor drive boards share one bus capacitor and one control board. The control board can control the operation of four motors simultaneously through the four motor drive boards, thereby improving the effect of synchronous control of the four motors and ensuring the coordination of the four motors.

[0019] 2. In the present invention, four motor drive boards, a control board and bus capacitors share a chassis to form an integrated structure. Compared with discrete controllers, the total volume of the controller is reduced, the cost is effectively reduced, and it is conducive to the development of automobiles towards lightweight, miniaturization and low cost; at the same time, the integrated controller reduces the external wiring between discrete controls, reduces the failure points, and improves the reliability of the product while saving volume and cost.

[0020] 3. In the present invention, a coolant flow channel is provided on the lower surface of the chassis, and the bus capacitor and the four motor drive boards can be cooled simultaneously by passing the coolant; at the same time, since the bus capacitor and the four motor drive boards share a cooling structure, the total volume of the controller is reduced, effectively reducing the cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 A schematic diagram of the structure of an integrated four-motor controller in this embodiment;

[0022] Figure 2 A structural schematic diagram of the control module in this embodiment;

[0023] Figure 3 A schematic diagram of a connection structure between a bus capacitor and a motor drive board in this embodiment;

[0024] Figure 4 A schematic diagram of the structure of the chassis backplane in this embodiment;

[0025] Figure 5 A schematic diagram of the structure of the coolant flow channel in this embodiment;

[0026] Figure 6 A schematic diagram of the structure of the chassis cover in this embodiment;

[0027] Figure 7 This is a principle topology diagram of the control board in this embodiment.

[0028] Figure markings: chassis 1, control board 2, bus capacitor 3, motor drive board 4, motor three-phase line interface 5, single-hole through-hole connector 6, coolant channel 7, coolant channel one 701, coolant channel two 702, coolant channel three 703, accommodating groove 704, boss 705, ridge 706, coolant interface 707, signal maintenance plug-in 8, low-voltage plug-in 9, resolver plug-in 10, isolation plate 11, chassis cover 12, single-hole through-hole connector hole 13, coolant interface hole 14, signal maintenance plug-in hole 15, low-voltage plug-in hole 16, motor three-phase line interface hole 17, resolver outlet hole 18, chassis back panel 19. DETAILED DESCRIPTION

[0029] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0030] Embodiment: An integrated four-motor controller, such as Figure 1-Figure 6 As shown, it includes a chassis 1 and a control module arranged in the chassis 1. The chassis 1 is a box-shaped structure with an open end and a accommodating cavity. The open end of the chassis 1 is installed with a chassis cover 12; the control module includes a control board 2, a bus capacitor 3, and four motor drive boards 4. The bus capacitor 3 is installed in the inner cavity of the chassis 1, that is, the bus capacitor 3 is installed on the inner bottom wall of the chassis 1 by bolts, and is located in the middle of the chassis 1, the lower surface of the bus capacitor 3 is in abutment with the inner bottom wall of the chassis 1, the control board 2 is installed above the bus capacitor 3, and two motor drive boards 4 are arranged on both sides of the bus capacitor 3; in the four motor drive boards 4, one side of each motor drive board 4 is electrically connected to the lead of the bus capacitor 3 through its lead, and the other side of each motor drive board 4 is electrically connected to the motor three-phase line interface 5 through its lead, and the lower surface of each motor drive board 4 is in abutment with the inner bottom wall of the chassis 1; one end of the bus capacitor 3 is electrically connected to a single-hole through-hole connector 6.

[0031] Among them, Figure 7 As shown, the main control chip of control board 2 adopts Infineon's AURIX TriCore quad-core microcontroller TC387. The four independent 32-bit TriCore CPUs can all operate at 300MHz, and the 9 DSADC channels are used to decode the resolver signal; the isolated power supply adopts the LM3481+single isolation transformer solution to generate 6 +16V and -7V isolated power supplies for driving IGBTs, and 1 +15V power supply is used to power the resolver excitation signal; the IGBT drive adopts an isolated driver chip with a low-voltage side ASC function. Under the conditions of low-voltage power failure or bus overvoltage, the motor controller can enter the ASC state to ensure torque safety.

[0032] Further, such as Figure 2 , Figure 3 As shown, a signal inspection plug-in 8, a low-voltage plug-in 9, and four resolver plug-ins 10 are installed on the control board 2. The signal inspection plug-in 8, the low-voltage plug-in 9 and the four resolver plug-ins 10 are all electrically connected to the control board 2, and the four resolver plug-ins 10 are respectively located on both sides of the control board 2, corresponding to the motor drive board 4.

[0033] Furthermore, an isolation plate 11 is installed on the upper surface of the bus capacitor 3, and the control board 2 is installed on the upper surface of the isolation plate 11. By providing the isolation plate 11, a short circuit between the bus capacitor 3 and the control board 2 is avoided.

[0034] Further, such as Figure 6 As shown, the chassis cover 12 is provided with a single-hole through-hole connector hole 13, a signal maintenance plug-in hole 15 and a low-voltage plug-in hole 16; the single-hole through-hole connector hole 13 is provided to facilitate the placement of the single-hole through-hole connector 6; the signal maintenance plug-in hole 15 is provided to facilitate the placement of the signal maintenance plug-in 8; the low-voltage plug-in hole 16 is provided to facilitate the placement of the low-voltage plug-in 9.

[0035] Further, such as Figure 1 , Figure 4 As shown, a motor three-phase line interface hole 17 and a resolver outlet hole 18 are provided on both sides of the chassis 1. The motor three-phase line interface hole 17 corresponds to the motor three-phase line interface 5, that is, four motor three-phase line interface holes 17 are provided, so that the three-phase wire harness of the motor passes through the motor three-phase line interface hole 17 and is plugged into the motor three-phase line interface 5, thereby realizing the connection between the motor and the motor drive board 4; there are two resolver outlet holes 18, which correspond to the resolver plug-in 10, and the resolver wire harness passes through the resolver outlet hole 18 and is plugged into the resolver plug-in 10.

[0036] Furthermore, the integrated four-motor controller has a square structure with dimensions of: length 536mm*width 536mm*height 249mm.

[0037] In the above-mentioned integrated four-motor controller, a design is adopted in which four motor drive boards 4 share one bus capacitor 3 and one control board 2. The control board 2 can control the operation of four motors simultaneously through the four motor drive boards 4, thereby improving the effect of synchronous control of the four motors and ensuring the coordination of the four motors. At the same time, the four motor drive boards 4, the control board 2 and the bus capacitor 3 share one chassis 1 to form an integrated structure. Compared with discrete controllers, the total volume of the controller is reduced, the cost is effectively reduced, and it is conducive to the development of automobiles towards lightweight, miniaturization and low cost; at the same time, the integrated controller reduces the external wiring between discrete controls, reduces the failure points, and improves the reliability of the product while saving volume and cost.

[0038] Furthermore, the chassis 1 is made of a heat-conducting material, such as a metal material, so that the chassis 1 has a certain heat-conducting effect, and can conduct heat to the coolant flow channel 7, and dissipate heat through the coolant; Figure 5 As shown, a coolant flow channel 7 is provided on the lower surface of the chassis 1, and the bus capacitor 3 and the four motor drive boards 4 can be cooled simultaneously by passing the coolant; at the same time, since the bus capacitor 3 and the four motor drive boards 4 share a cooling structure, the total volume of the controller is reduced, effectively reducing the cost.

[0039] Specifically, the coolant channel 7 includes a coolant channel 1 701, a coolant channel 2 702 and a coolant channel 3 703. The coolant channel 1 701, the coolant channel 2 702 and the coolant channel 3 703 are connected to form an S-shaped structure. The coolant channel 1 701 and the coolant channel 3 703 are provided with a receiving groove 704 recessed in the coolant channel 7 at the position corresponding to the motor drive board 4. The receiving groove 704 is provided with a plurality of convex columns 705 distributed in an array. The convex columns 705 are located on the fan heat sink of the IGBT on the motor drive board 4. The convex columns 705 are perpendicular to the coolant channel 7. The coolant channel 2 702 is provided with a plurality of convex ridges 706 parallel to and integrated with the chassis 1 at the position corresponding to the bus capacitor 3. The convex ridges 706 are arranged along the flow direction of the coolant in the coolant channel 2 702.

[0040] By providing a coolant flow channel 1 701, a coolant flow channel 2 702 and a coolant flow channel 3 703 and connecting them to form an S-shaped structure, the coolant cooling path is extended to improve the cooling effect of the bus capacitor 3 and the motor drive board 4; at the same time, by providing a convex column 705, the fan heat sink of the IGBT is directly in contact with the coolant to improve the cooling effect; by providing a convex ridge 706 to increase the contact area with the coolant, the cooling effect of the bus capacitor 3 is improved.

[0041] Furthermore, the flow channel diameter at the connection between coolant flow channel 1 701 and coolant flow channel 2 702 is smaller than the flow channel diameters of coolant flow channel 1 701 and coolant flow channel 2 702, and the flow channel diameter at the connection between coolant flow channel 3 703 and coolant flow channel 2 702 is smaller than the flow channel diameters of coolant flow channel 3 703 and coolant flow channel 2 702; by changing the sudden change of the flow channel diameter, the flow rate of the coolant is changed. On the one hand, it is convenient for the coolant to flow through coolant flow channel 2 702 effectively and quickly, so that the coolant is in full contact with the surface of coolant flow channel 3 703, thereby improving the cooling effect; on the other hand, it cooperates with the convex ridge 706 to form a certain disturbance effect, thereby improving the cooling effect.

[0042] Furthermore, the free end of the coolant flow channel 1 701 and the free end of the coolant flow channel 3 703 are both connected to a coolant interface 707, and the two coolant interfaces 707 extend to the outside of the open end of the chassis 1. Accordingly, the chassis cover 12 is provided with a coolant interface hole 14 for placing the coolant interface 707. The two coolant interfaces 707 are connected to the coolant flow channel 7, and are respectively used for the coolant to flow in and out.

[0043] Furthermore, a chassis back plate 19 for sealing the coolant flow channel 7 is installed on the lower surface of the chassis 1 .

[0044] The above is only a preferred embodiment of the present invention, and the protection scope of the present invention is not limited to the above embodiments. All technical solutions under the concept of the present invention belong to the protection scope of the present invention. It should be pointed out that for ordinary technicians in this technical field, some improvements and modifications without departing from the principle of the present invention should also be regarded as the protection scope of the present invention.

Claims

1. An integrated four-motor controller, comprising a chassis (1) having a heat-conducting effect, and a control module arranged in the chassis (1), characterized in that: The control module comprises a control board (2), a bus capacitor (3), and four motor drive boards (4); the bus capacitor (3) is installed in the inner cavity of the chassis (1); the control board (2) is installed above the bus capacitor (3); two motor drive boards (4) are arranged on both sides of the bus capacitor (3); one side of the motor drive board (4) is electrically connected to the bus capacitor (3); the other side of the motor drive board (4) is electrically connected to the motor three-phase line interface (5); one end of the bus capacitor (3) is electrically connected to a single-hole through-hole connector (6); a coolant flow channel (7) is arranged on the lower surface of the chassis (1); and the bus capacitor (3) and the four motor drive boards (4) are cooled by passing coolant.

2. The integrated four-motor controller according to claim 1, characterized in that: The coolant flow channel (7) comprises a coolant flow channel 1 (701), a coolant flow channel 2 (702) and a coolant flow channel 3 (703); the coolant flow channel 1 (701), the coolant flow channel 2 (702) and the coolant flow channel 3 (703) are connected to form an S-shaped structure; the coolant flow channel 1 (701) and the coolant flow channel 3 (703) are provided with a receiving groove (704) recessed in the coolant flow channel (7) at positions corresponding to the motor drive plate (4); the receiving groove (704) is provided with a plurality of convex columns (705) distributed in an array; the convex columns (705) are perpendicular to the coolant flow channel (7); the coolant flow channel 2 (702) is provided with a plurality of convex ridges (706) parallel to and integral with the chassis (1) at a position corresponding to the busbar capacitor (3); the convex ridges (706) are arranged along the flow direction of the coolant in the coolant flow channel 2 (702).

3. The integrated four-motor controller according to claim 2, characterized in that: The flow channel diameter at the connection between the coolant flow channel one (701) and the coolant flow channel two (702) is smaller than the flow channel diameters of the coolant flow channel one (701) and the coolant flow channel two (702), and the flow channel diameter at the connection between the coolant flow channel three (703) and the coolant flow channel two (702) is smaller than the flow channel diameters of the coolant flow channel three (703) and the coolant flow channel two (702).

4. The integrated four-motor controller according to claim 2, characterized in that: The free end of the cooling liquid channel 1 (701) and the free end of the cooling liquid channel 3 (703) are both connected to a cooling liquid interface (707), and the two cooling liquid interfaces (707) extend to the outside of the open end of the chassis (1).

5. The integrated four-motor controller according to claim 1, characterized in that: The control panel (2) is provided with a signal inspection plug-in (8), a low voltage plug-in (9), and four resolver plug-ins (10) which are electrically connected thereto.

6. The integrated four-motor controller according to claim 1, characterized in that: An isolation plate (11) is installed on the upper surface of the bus capacitor (3), and the control board (2) is installed on the upper surface of the isolation plate (11).

7. The integrated four-motor controller according to claim 1, characterized in that: The open end of the chassis (1) is provided with a chassis cover (12), and the chassis cover (12) is provided with a single-hole through-hole connector hole (13), a coolant interface hole (14), a signal maintenance plug-in hole (15), and a low-voltage plug-in hole (16).

8. The integrated four-motor controller according to claim 1, characterized in that: A motor three-phase line interface hole (17) and a resolver outlet hole (18) are provided on both sides of the chassis (1); the motor three-phase line interface hole (17) corresponds to the motor three-phase line interface (5); and the resolver outlet hole (18) is located between the two motor three-phase line interface holes (17).

9. The integrated four-motor controller according to claim 1, characterized in that: A chassis back plate (19) for sealing the cooling liquid flow channel (7) is installed on the lower surface of the chassis (1).

10. The integrated four-motor controller according to claim 1, characterized in that: The integrated four-motor controller has a square structure with dimensions of: length 536mm*width 536mm*height 249mm.

Images