Motor system with axially arranged motor controller and motor controller

Abstract

A power chip, a driving circuit, a discharging unit and the like are integrated through a PCB, the motor controller is divided into an upper cavity and a lower cavity, the middle of the motor controller is of a water channel structure, the power chip board is placed in the upper cavity in a shell attaching mode, a capacitor and filter assembly is encapsulated in the lower cavity, a cavity is formed in the center of an inverter, and the power chip board is arranged in the cavity. And integration with a motor is facilitated. The form stray parameter of the power integrated board card is lower, stepless power expansion is more convenient to realize, and high performance is further realized; meanwhile, due to high integration, the size and the weight are lower, high power density can be achieved, the whole vehicle carrying performance is improved, the process is complex and the transportation cost is high in the mode that original independent parts are produced in various places and then connected through bolts in an assembly factory, the motor controller and the motor can be produced in one place in a concentrated mode, the production process is simplified, and the material cost is lower. The motor controller and the motor are axially installed, the surface area of the motor controller is reduced, the size is reduced, and whole vehicle carrying is facilitated.

Description

Technical Field

[0001] The present invention belongs to the technical field of motor control for new energy vehicles, and in particular relates to a motor system and a motor controller in which a motor controller is axially arranged. Background Art

[0002] At present, the motor controller of new energy vehicles is developing towards high performance, high power density and low cost. The motor controllers on the market usually use independent components for bolt connection, and the power density and performance improvement have reached a bottleneck, and the assembly is complicated.

[0003] The conventional circuit of the motor controller of a new energy vehicle is composed of a bus capacitor 3, a power module 2, a drive unit 1, a control unit 4 and a discharge unit 7. The DC voltage of the high-voltage battery 6 smoothes the ripple through the bus capacitor 3, and is chopped into a three-phase sine wave through the three-phase six-switch power module 2, and then drives the motor 5 to rotate. Among them, the control signal of the three-phase six-switch power module 2 is generated by the control unit 4, and after the power amplification of the drive unit 1, it drives the power switch 1, and then drives the motor, and finally realizes the conversion of the electrical energy of the high-voltage battery 6 into mechanical energy to drive the operation of the new energy vehicle, such as Figure 1 shown.

[0004] Usually, the power module is an independent package, and the packaging forms are plastic package and frame type. Both packaging forms encapsulate the MOS / IGBT chip in an independent structure. The problem with this packaging is that it is large in size, has large stray parameters, and is heavy. It is also inconvenient to install and has high cost. The drive unit is also an independent package, which is PCB-mounted. It is connected to the power module by soldering and bolts. The control unit is also an independent package, which is PCB-mounted, and is connected to the drive unit through a flat cable. The busbar capacitor is also an independent package, which is plastic-sealed and connected to the power module by bolts. The connection is complex, the stray parameters are large, and the weight is heavy. Other filter units and discharge units are also independent packages, connected by bolts.

[0005] In summary, the conventional motor controller on the market, which is connected by bolts on each independent component, can no longer meet the needs of high-performance vehicles. There is an urgent need to break through the conventional component packaging and assembly methods to achieve higher performance, higher power density and lower cost for the motor controller. Summary of the invention

[0006] The purpose of the present invention is to provide a motor system and a motor controller with an axially arranged motor controller, so as to solve the problem of improving the performance and power density of the motor controller while reducing the cost.

[0007] The objective of the present invention is achieved through the following technical solutions:

[0008] A motor controller includes an inverter, wherein the inverter is composed of a power substrate assembly, a capacitor filter and an inverter box side wall assembly 2, an inverter hollow inner shell 3, a power wiring seat 4, a low-voltage wiring seat 5, a cooling inlet and outlet water pipe 6, a three-phase copper busbar 7, an inverter lower box shell 8, a control substrate 11, a shielding plate 12, and an inverter upper box shell 13;

[0009] The power substrate assembly is arranged on the upper outer wall of the capacitor filter and inverter box side wall assembly 2; the capacitor filter and inverter box side wall assembly 2 is composed of a capacitor core 2-1, a filter core 2-2, a shell 2-3 with a built-in water channel, and an inverter side wall shell 2-4, and can be integrally potted by resin to form a capacitor and filter assembly; the power substrate 1 is arranged above the built-in circulating water channel of the shell 2-3 with a built-in water channel, and the shell 2-3 with a built-in water channel circulates with the external coolant through the cooling inlet and outlet water pipes 6;

[0010] The control substrate 11 is arranged on the top layer of the inverter, and a shielding plate 12 is arranged between the control substrate 11, the capacitor filter and the inverter box side wall assembly 2; the power terminal block 4, the low-voltage terminal block 5 and the cooling water inlet and outlet pipes 6 are arranged on the side wall of the motor controller, and the three-phase copper busbar 7 is arranged on the lower shell 8 of the motor controller, extending out of the wall through the hole 8-1 of the lower shell 8 of the motor controller to be connected with the three phases of the motor; the inverter hollow inner shell 3 is connected with the inverter lower box shell 8 and the inverter upper box shell 13 to form a closed inverter shell.

[0011] Furthermore, the shell 2 - 3 with the built-in water channel is welded to the inverter side wall shell 2 - 4 into a whole, and a hollow rectangular inner cavity is formed at the bottom.

[0012] Furthermore, the inner cavity is evenly arranged with a plurality of capacitor cores 2-1 and a plurality of filter cores 2-2.

[0013] Furthermore, the filter core 2 - 2 is arranged next to the power wiring socket 4 .

[0014] Furthermore, the inverter hollow inner shell 3 is fixed to the inverter lower box shell 8 and the inverter upper box shell 13 by welding.

[0015] Furthermore, the power substrate assembly is composed of a three-phase full bridge, and the U phase, V phase, and W phase correspond to three identical power substrates 1, in which the power chip is buried in the middle layer and the drive circuit is arranged on the upper layer. The power substrate 1 is composed of an upper multi-layer drive circuit layer 1-1 and a lower power module layer 1-2.

[0016] Furthermore, the driving circuit layer 1-1 is an ordinary multi-layer FR4 circuit board, the electronic device and discharge unit 1-11 is a plurality of electronic devices and discharge units arranged on the upper layer, the low-voltage connector 1-13 is arranged on one side of the electronic device and discharge unit 1-11 to provide power and signal transmission for the driving board, the FR4 insulating layer 1-14 is located below the low-voltage connector 1-13, and the welding copper layer 1-12 is located below the FR4 insulating layer 1-14.

[0017] Furthermore, the power module layer 1-2 is a circuit board with embedded semiconductor chips, including a semiconductor chip 1-23, embedded insulating PP layer II 1-29 and insulating PP layer I 1-28, and connecting the upper copper layer 1-21 and the lower copper layer 1-210 through copper-plated copper pillars 1-22 via holes.

[0018] Furthermore, the insulating heat-conducting layer 1-27 and the insulating layer 1-20 are provided to insulate the driving circuit layer 1-1 from the power module layer 1-2.

[0019] A motor system with an axially arranged motor controller includes the motor controller described above. The shaft of the motor 9 passes through the inverter hollow inner shell 3 of the inverter to form a whole.

[0020] Compared with the prior art, the present invention has the following beneficial effects:

[0021] The present invention provides a high-power density motor controller, which integrates power chips, drive circuits, discharge units, etc. through a PCB board. The motor controller is divided into two upper and lower cavities, with a water channel structure in the middle. The upper cavity is attached to the shell to place the power chip board, and the lower cavity is encapsulated with capacitors and filter assemblies. There is a cavity in the center of the inverter, which is conducive to integration with the motor. This power integrated board has lower stray parameters and is more convenient to achieve stepless power expansion, thereby achieving high performance; at the same time, high integration leads to lower volume and weight, which can achieve high power density and improve vehicle carrying performance. The original method of producing independent components in various places and then bolting them together in the final assembly plant is complex and has high transportation costs. This device can be concentrated in one place for production, simplifying the production process, and lowering the material cost. The motor controller is installed axially with the motor, which reduces the surface area of ​​the motor controller and the volume, making it more conducive to vehicle carrying. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments are briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without creative work.

[0023] Figure 1Motor controller power topology example circuit diagram;

[0024] Figure 2 Schematic diagram of the original components of IGBT G gate, C collector, E emitter;

[0025] Figure 3 Schematic diagram of the original MOS components: G gate, S source, D drain;

[0026] Figure 4 Front view of high power density inverter;

[0027] Figure 5 Side view of high power density inverter;

[0028] Figure 6 Side view of the power baseboard assembly;

[0029] Figure 7 Motor system, schematic diagram of the motor shaft passing through the hollow part of the inverter;

[0030] Figure 8 Schematic diagram of the motor system, with the inverter arranged on the side wall of the motor.

[0031] In the figure, 1. Power substrate 2. Capacitor filter and inverter box side wall assembly 3. Inverter hollow inner shell 4. Power terminal block 5. Low voltage terminal block 6. Cooling inlet and outlet pipes 7. Three-phase copper busbar 8. Inverter lower box shell 9. Motor 10. Motor shaft 11. Control substrate 12. Shielding plate 13. Inverter upper box shell 1-1. Drive circuit layer 1-2. Power module layer 1-11. Electronic devices and discharge unit 1-12. Welding copper layer 1-13. Low voltage connector 1-1 4. FR4 insulation layer 1-20. Insulation layer 1-21. Upper copper layer 1-22. Copper pillar with copper plating in via hole 1-23. Semiconductor chip 1-24. Negative power terminal 1-25. Positive power terminal 1-26. Three-phase output power terminal 1-27. Insulation thermal conductive layer 1-28. Insulation PP layer I 1-29. Insulation PP layer II 1-210. Lower copper layer 2-1. Capacitor core 2-2. Filter core 2-3. Shell with built-in water channel 2-4. Inverter side wall shell. DETAILED DESCRIPTION

[0032] The present invention will be further described below in conjunction with embodiments:

[0033] The present invention provides a high power density motor controller, which integrates power chips, drive circuits, discharge units, etc. through a PCB board. The motor controller is divided into two upper and lower cavities, with a water channel structure in the middle. The upper cavity is attached to the shell to place the power chip board, and the lower cavity is encapsulated with capacitors and filter assemblies. There is a cavity in the center of the inverter, which is conducive to integration with the motor. This power integrated board has lower stray parameters and is more convenient to achieve stepless power expansion, thereby achieving high performance. At the same time, high integration leads to lower volume and weight, which can achieve high power density and improve vehicle carrying capacity. The original method of producing independent components in various places and then bolting them in the final assembly plant is complex and has high transportation costs. The present invention can be concentrated in one place for production, simplifying the production process, and lowering the material cost. The motor controller is axially installed with the motor, which reduces the surface area of ​​the motor controller and the volume, and is more conducive to vehicle carrying.

[0034] The motor controller of the present invention includes a high power density inverter, such as Figure 4 and Figure 5 As shown, it consists of a power substrate assembly, a capacitor filter and inverter box side wall assembly 2, an inverter hollow inner shell 3, a power terminal block 4, a low-voltage terminal block 5, a cooling inlet and outlet water pipe 6, a three-phase copper busbar 7, an inverter lower box shell 8, a control substrate 11, a shielding plate 12 and an inverter upper box shell 13.

[0035] Among them, the capacitor filter and inverter case side wall assembly 2 is composed of four parts: a capacitor core 2-1, a filter core 2-2, a shell 2-3 with a built-in water channel, and an inverter side wall shell 2-4. The shell 2-3 with a built-in water channel is welded to the inverter side wall shell 2-4 as a whole, and a hollow rectangular inner cavity is formed at the bottom. A plurality of capacitor cores 2-1 and a plurality of filter cores 2-2 are evenly arranged in the inner cavity, and the filter core 2-2 must be arranged next to the power terminal block 4. Finally, the capacitor and filter assembly is formed by integral resin potting. The power substrate assembly is arranged above the shell 2-3 with a built-in water channel, so that the shell 2-3 with a built-in water channel can simultaneously dissipate heat to the capacitor and filter assembly below, and can also dissipate heat to the power substrate 1 above, which helps to improve the power density.

[0036] The power substrate assembly is attached to the upper outer wall of the capacitor filter and the inverter box side wall assembly 2, and can be soldered or silver sintered. The housing 2-3 with built-in water channel is a metal structure, with built-in circulating water channel, which circulates with external coolant through the cooling inlet and outlet pipes 6.

[0037] The control substrate 11 is arranged on the top layer of the inverter, and a shielding plate 12 is arranged between the control substrate 11, the capacitor filter and the inverter box side wall assembly 2 to shield high and low voltage signals and improve electromagnetic compatibility performance.

[0038] The power connection socket 4, the low voltage connection socket 5 and the cooling water inlet and outlet pipes 6 are arranged on the side wall of the motor controller, and the three-phase copper busbar 7 is arranged on the lower housing 8 of the motor controller, extending out of the wall through the hole 8-1 of the lower housing 8 of the motor controller, and connected with the three phases of the motor. The inverter hollow inner housing 3 is welded with the inverter lower box shell 8 and the inverter upper box shell 13 to form a closed inverter housing.

[0039] Power baseboard assembly, such as Figure 6 As shown, it is composed of a three-phase full bridge, and the U phase, V phase, and W phase correspond to three identical power substrates 1, in which the power chip is buried in the middle layer and the drive circuit is arranged on the upper layer. The power substrate 1 is composed of an upper multi-layer drive circuit layer 1-1 and a lower power module layer 1-2. The drive circuit layer 1-1 is an ordinary multi-layer FR4 circuit board, and the electronic device and discharge unit 1-11 are multiple electronic devices and discharge units arranged on the upper layer, such as drive chips, capacitors, resistors, transformers, etc. The low-voltage connector 1-13 is arranged on one side of the electronic device and discharge unit 1-11 to provide power and signal transmission for the drive board. The FR4 insulation layer 1-14 is located below the low-voltage connector 1-13, and the welding copper layer 1-12 is located below the FR4 insulation layer 1-14. The power module layer 1-2 is a circuit board with a semiconductor chip embedded, including a semiconductor chip 1-23, an embedded insulating PP layer II 1-29 and an insulating PP layer I 1-28, and connecting an upper copper layer 1-21 and a lower copper layer 1-210 through a copper-plated copper column 1-22 through a via hole. An insulating heat-conducting layer 1-27 and an insulating layer 1-20 are provided to insulate the drive circuit layer 1-1 from the power module layer 1-2. It also includes a negative power terminal 1-24, a positive power terminal 1-25, and a three-phase output power terminal 1-26.

[0040] The motor system composed of the high power density inverter designed by the present invention is as follows Figure 7 As shown, the shaft of the motor 9 passes through the hollow part of the inverter to form a whole, which has better carrying performance. The motor system consists of three parts: the motor 9, the motor shaft 10 and the high power density inverter.

[0041] If the motor and inverter are not arranged axially due to limited layout space, the central hole of the inverter can be eliminated and arranged on the side wall of the motor, such as Figure 8 shown.

[0042] The high power density motor controller of the present invention integrates power chip, drive circuit, discharge unit, etc. through PCB board. The motor controller is divided into upper and lower cavities, with a water channel structure in the middle. The upper cavity is attached to the shell to place the power chip board, and the lower cavity is encapsulated with capacitors and filter assembly. There is a cavity in the center of the inverter, which is conducive to integration with the motor. The motor system designed based on the motor controller of the present invention is more conducive to vehicle installation.

[0043] Note that the above are only preferred embodiments of the present invention and the technical principles used. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein, and that various obvious changes, readjustments and substitutions can be made by those skilled in the art without departing from the scope of protection of the present invention. Therefore, although the present invention has been described in more detail through the above embodiments, the present invention is not limited to the above embodiments, and may include more other equivalent embodiments without departing from the concept of the present invention, and the scope of the present invention is determined by the scope of the appended claims.

Claims

1. A motor controller, characterized in that: The inverter comprises an inverter, which is composed of a power substrate assembly, a capacitor filter and an inverter box side wall assembly (2), an inverter hollow inner shell (3), a power wiring seat (4), a low-voltage wiring seat (5), a cooling water inlet and outlet pipe (6), a three-phase copper busbar (7), an inverter lower box shell (8), a control substrate (11), a shielding plate (12) and an inverter upper box shell (13); The power substrate assembly is arranged on the upper outer wall of the capacitor filter and inverter case side wall assembly (2) by a shell; the capacitor filter and inverter case side wall assembly (2) is composed of a capacitor core (2-1), a filter core (2-2), a housing with a built-in water channel (2-3) and an inverter side wall housing (2-4), and can be integrally encapsulated by resin to form a capacitor and filter assembly; the power substrate (1) is arranged above the built-in circulating water channel of the housing with a built-in water channel (2-3), and the housing with a built-in water channel (2-3) circulates with external cooling liquid through cooling inlet and outlet water pipes 6; The control substrate (11) is arranged on the uppermost layer of the inverter, and a shielding plate (12) is arranged between the control substrate (11), the capacitor filter and the inverter box side wall assembly (2); the power wiring seat (4), the low-voltage wiring seat (5) and the cooling water inlet and outlet pipes (6) are arranged on the side wall of the motor controller, and the three-phase copper busbar (7) is arranged on the lower shell (8) of the motor controller, extending out of the wall through the hole (8-1) of the lower shell (8) of the motor controller to be connected with the three phases of the motor; the inverter hollow inner shell (3) is connected with the inverter lower box shell (8) and the inverter upper box shell (13) to form a closed inverter shell.

2. A motor controller according to claim 1, characterized in that: The housing (2-3) with the built-in water channel and the inverter side wall housing (2-4) are welded into a whole, and a hollow rectangular inner cavity is formed at the bottom.

3. A motor controller according to claim 2, characterized in that: The inner cavity evenly arranges a plurality of capacitor cores (2-1) and a plurality of filter cores (2-2).

4. A motor controller according to claim 3, characterized in that: The filter core (2-2) is arranged next to the power wiring socket (4).

5. A motor controller according to claim 1, characterized in that: The inverter hollow inner shell 3 is fixed to the inverter lower box shell (8) and the inverter upper box shell (13) by welding.

6. A motor controller according to claim 1, characterized in that: The power substrate assembly is composed of a three-phase full bridge, wherein the U phase, the V phase and the W phase correspond to three identical power substrates (1), wherein the power chip is embedded in the middle layer and the drive circuit is arranged in the upper layer. The power substrate 1 is composed of an upper multi-layer drive circuit layer (1-1) and a lower power module layer (1-2).

7. A motor controller according to claim 6, characterized in that: The driving circuit layer (1-1) is a multi-layer FR4 circuit board, the electronic device and discharge unit (1-11) are a plurality of electronic devices and discharge units arranged on an upper layer, the low-voltage connector (1-13) is arranged on one side of the electronic device and discharge unit (1-11) to provide power and signal transmission for the driving board, the FR4 insulation layer 1-14 is located below the low-voltage connector (1-13), and the welding copper layer (1-12) is located below the FR4 insulation layer (1-14).

8. A motor controller according to claim 6, characterized in that: The power module layer (1-2) is a circuit board with a semiconductor chip embedded therein, comprising a semiconductor chip (1-23), an embedded insulating PP layer II (1-29) and an insulating PP layer I (1-28), and connecting an upper copper layer (1-21) and a lower copper layer (1-210) via a copper-plated copper column (1-22) through a via hole.

9. A motor controller according to claim 6, characterized in that: The insulating heat-conducting layer (1-27) and the insulating layer (1-20) are provided so as to insulate the driving circuit layer (1-1) from the power module layer (1-2).

10. A motor system with an axially arranged motor controller, characterized in that: It comprises a motor controller as claimed in claim 1, wherein the shaft of the motor (9) passes through the hollow inner shell 3 of the inverter to form a whole.

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