Integrated multistage EMC filter for new energy vehicle motor controller

Abstract

The invention discloses an integrated multistage EMC filter for a motor controller of a new energy vehicle, the integrated multistage EMC filter for the motor controller of the new energy vehicle comprises a filter shell, a runway type first-stage magnetic ring is fixedly mounted on the filter shell, and a positive electrode copper bar assembly and a negative electrode copper bar assembly are mounted on the upper surface of the filter shell in parallel; the ends of the positive electrode copper bar assembly and the negative electrode copper bar assembly are provided with first-stage filtering circuit boards, the ends of the positive electrode copper bar assembly and the negative electrode copper bar assembly penetrate through the runway type first-stage magnetic rings, and the positions, close to the other ends, of the positive electrode copper bar assembly and the negative electrode copper bar assembly are sleeved with split type second-stage magnetic rings. The side, away from the filter shell, of the split type secondary magnetic ring is covered with a secondary magnetic ring pressing plate, and the outer side of the secondary magnetic ring pressing plate is surrounded by a secondary filter circuit board. The device has the advantages of simple and compact structure, convenience and quickness in modularized manufacturing and the like.

Description

Technical Field

[0001] The present invention relates to the technical field of motor controllers, and in particular to an integrated multi-stage EMC filter for a motor controller of a new energy vehicle. Background Art

[0002] At present, my country's new energy vehicle industry is booming, and the penetration rate of new energy vehicles has exceeded 50%, and it is showing an upward trend. As a key component of the electric drive unit of new energy vehicles, the motor controller usually uses power semiconductors such as IGBT and SiC for pulse width modulation (PWM) control to adjust the three-phase output voltage of the motor controller. The high current change rate di / dt and voltage change rate du / dt caused by the rapid switching of power semiconductor devices will inevitably generate electromagnetic noise, which will not only make the equipment itself unable to meet the EMC standard threshold requirements, but also affect other on-board equipment through the high-voltage power harness.

[0003] Therefore, an integrated multi-stage EMC filter for a new energy vehicle motor controller is provided to solve the above problems. Summary of the invention

[0004] The technical problem to be solved by the present invention is that the high current change rate di / dt and voltage change rate du / dt caused by the rapid switching of power semiconductor devices will inevitably generate electromagnetic noise, which will not only make the equipment itself unable to meet the EMC standard threshold requirements, but also affect other on-board equipment through the high-voltage power supply harness. Therefore, an integrated multi-stage EMC filter for a new energy vehicle motor controller is provided, and the integrated multi-stage EMC filter for a new energy vehicle motor controller includes: A filter housing, wherein a magnetic ring through hole is provided on the filter housing, a runway-type primary magnetic ring is fixedly installed in the lower part of the magnetic ring through hole, a positive copper bar assembly and a negative copper bar assembly are installed in parallel on the upper surface of the filter housing, one end of the positive copper bar assembly and the negative copper bar assembly pass through the runway-type primary magnetic ring, a primary filter circuit board is installed at the end of the positive copper bar assembly and the negative copper bar assembly, the primary filter circuit board is provided with a primary filter circuit, the positive copper bar assembly and the negative copper bar assembly are sleeved with a split secondary magnetic ring near the other end, a side cover of the split secondary magnetic ring away from the filter housing is provided with a secondary magnetic ring pressure plate, the outer side of the secondary magnetic ring pressure plate is surrounded by a secondary filter circuit board, a secondary filter circuit is provided on the secondary filter circuit board, the primary filter circuit board is provided with a secondary filter circuit, the primary filter circuit and the secondary filter circuit are connected to the positive copper bar assembly and the negative copper bar assembly for positive and negative circuits through fastening screws.

[0005] Furthermore, the split secondary magnetic ring includes a split ferrite magnetic ring upper half and a split ferrite magnetic ring lower half, a magnetic ring mounting groove is opened on the filter housing, the split ferrite magnetic ring lower half is fixedly connected to the magnetic ring mounting groove through a glue pouring process, and the split ferrite magnetic ring upper half is fixedly connected to the secondary magnetic ring pressure plate through a glue pouring process.

[0006] Furthermore, the negative copper bar assembly includes a first negative copper bar connecting terminal, a second negative copper bar connecting terminal, a negative copper bar connecting copper column, a negative copper bar insulating plastic-dipped layer and a negative copper bar, the first negative copper bar connecting terminal and the second negative copper bar connecting terminal are welded to the negative copper bar at the same time, the negative copper bar connecting copper column and the negative copper bar are interference-connected, and the negative copper bar insulating plastic-dipped layer is sleeved on the negative copper bar.

[0007] Furthermore, the positive copper bar assembly includes a first positive copper bar connection terminal, a second positive copper bar connection terminal, a positive copper bar connection copper column, a positive copper bar insulation plastic-dip layer and a positive copper bar, the first positive copper bar connection terminal and the second positive copper bar connection terminal are welded to the positive copper bar at the same time, the positive copper bar connection copper column and the positive copper bar are interference-connected, and the positive copper bar insulation plastic-dip layer is sleeved on the positive copper bar.

[0008] Furthermore, the first-level filter circuit board is welded with a first negative filter common mode capacitor, a second negative filter common mode capacitor, a third negative filter common mode capacitor, a first positive filter common mode capacitor, a second positive filter common mode capacitor, a third positive filter common mode capacitor and a first-level filter differential mode capacitor constituting a first-level filter circuit; The capacitance values ​​of the first negative electrode filtering common mode capacitor, the second negative electrode filtering common mode capacitor and the third negative electrode filtering common mode capacitor are all 2.2 nF; The capacitance values ​​of the first positive electrode filtering common mode capacitor, the second positive electrode filtering common mode capacitor and the third positive electrode filtering common mode capacitor are all 2.2 nF; The capacitance value of the first-stage filtering differential mode capacitor is 33nF.

[0009] Furthermore, the secondary filter circuit board is welded with a fourth positive filter common mode capacitor, a secondary filter differential mode capacitor and a fourth negative filter common mode capacitor constituting a secondary filter circuit; The capacitance value of the fourth positive electrode filtering common mode capacitor is 100nF; The capacitance value of the fourth negative electrode filtering common mode capacitor is 100nF; The capacitance value of the secondary filtering differential mode capacitor is 6.8 nF.

[0010] Furthermore, the racetrack-shaped primary magnetic ring is made of nanocrystalline material, and the racetrack-shaped primary magnetic ring and the filter housing are fixedly connected by glue filling.

[0011] Further, it also includes a first fastening screw, a second fastening screw, a third fastening screw, a fourth fastening screw, a fifth fastening screw, a sixth fastening screw, a seventh fastening screw, an eighth fastening screw, a ninth fastening screw, a tenth fastening screw, an eleventh fastening screw, a twelfth fastening screw, a thirteenth fastening screw, a fourteenth fastening screw, a fifteenth fastening screw and a sixteenth fastening screw; The first fastening screw is used to fix and lock the primary filter circuit board and the first negative copper busbar connection terminal to the filter housing; The second fastening screw is used to fix and lock the primary filter circuit board and the first positive copper busbar connection terminal to the filter housing; The third fastening screw is used to fix and lock the negative copper busbar assembly and the negative electrode of the high-voltage DC busbar; The fourth fastening screw is used to fix and lock the positive copper busbar assembly and the positive electrode of the high-voltage DC busbar; The fifth fastening screw is used to fix and lock the primary filter circuit board to the controller housing for grounding; The sixth fastening screw is used to fix and lock the second negative copper bar connecting terminal and the primary filter circuit board to the filter housing; The seventh fastening screw is used to fix and lock the primary filter circuit board to the controller housing for grounding; The eighth fastening screw is used to fix and lock the secondary filter circuit board to the controller housing for grounding; The ninth fastening screw is used to fix and lock the secondary magnetic ring pressing plate and the second positive copper bar connecting terminal to the filter housing; The tenth fastening screw is used to fix and lock the secondary filter circuit board onto the negative copper busbar connecting copper column. The eleventh fastening screw is used to fix and lock the secondary filter circuit board onto the positive copper busbar connecting copper column; The twelfth fastening screw is used to lock the filter housing and the secondary magnetic ring pressure plate together on the motor controller housing; The thirteenth fastening screw is used to fix and lock the secondary magnetic ring pressure plate to the filter housing; The fourteenth fastening screw is used to lock the filter housing and the motor controller housing, and is also used as a grounding point for the fourth positive filter common mode capacitor; The fifteenth fastening screw and the sixteenth fastening screw are used to fix and lock the filter output end to the subsequent DC-Link.

[0012] Furthermore, the specific connection method of the primary filter circuit and the secondary filter circuit includes: One end of the first positive filtering common-mode capacitor is electrically connected to the positive electrode of the DC high-voltage bus, and the other end is grounded; One end of the second positive filter common mode capacitor is electrically connected to the positive electrode of the DC high voltage bus, and the other end is grounded; One end of the third positive filtering common mode capacitor is electrically connected to the positive electrode of the DC high voltage bus, and the other end is grounded; One end of the first negative electrode filtering common mode capacitor is electrically connected to the negative electrode of the DC high voltage bus, and the other end is grounded; One end of the second negative electrode filtering common mode capacitor is electrically connected to the negative electrode of the DC high voltage bus, and the other end is grounded; One end of the third negative electrode filtering common mode capacitor is electrically connected to the negative electrode of the DC high voltage bus, and the other end is grounded; One end of the primary filtering differential mode capacitor is electrically connected to the positive electrode of the DC high voltage bus, and the other end is electrically connected to the negative electrode of the DC high voltage bus; One end of the secondary filtering differential mode capacitor is electrically connected to the positive electrode of the DC high voltage bus, and the other end is electrically connected to the negative electrode of the DC high voltage bus; One end of the fourth negative electrode filtering common mode capacitor is electrically connected to the negative electrode of the DC high voltage bus, and the other end is grounded; One end of the fourth positive filtering common mode capacitor is electrically connected to the positive electrode of the DC high voltage bus, and the other end is grounded; A racetrack-type primary magnetic ring is sleeved on the DC high-voltage busbar at the front end of the first positive filter common-mode capacitor; a split secondary magnetic ring is also sleeved on the DC busbar between the primary filter differential-mode capacitor and the secondary filter differential-mode capacitor.

[0013] The implementation of the present invention has the following beneficial effects: The integrated multi-stage EMC filter design of the present invention has each part manufactured separately and connected by fixed connecting screws, so as to realize modular production and assembly of the product; the positive and negative circuits use fixed connecting screws to lock the filter circuit board and the connecting terminals welded on the positive and negative busbars on the filter housing together, so as to realize the rapid access of the positive and negative circuits to the filter circuit, and at the same time, multi-point grounding is adopted to reduce the length of the grounding path and realize better EMC filtering effect; the multi-stage EMC filter design can better suppress the noise interference caused by the switching of power modules such as SiC and IGBT of the motor controller. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 It is a three-dimensional structural schematic diagram of an integrated multi-stage EMC filter for a motor controller of a new energy vehicle according to the present invention; Figure 2 It is an exploded diagram of the integrated multi-stage EMC filter for the motor controller of a new energy vehicle of the present invention; Figure 3It is a schematic diagram of the positive copper busbar assembly of the integrated multi-stage EMC filter for the motor controller of a new energy vehicle of the present invention; Figure 4 It is a schematic diagram of the negative copper busbar assembly of the integrated multi-stage EMC filter for the motor controller of a new energy vehicle of the present invention; Figure 5 It is a relative position relationship diagram of the positive and negative copper busbar components and the magnetic ring of the integrated multi-stage EMC filter for the motor controller of the new energy vehicle of the present invention; Figure 6 It is a circuit diagram of a filter circuit of an integrated multi-stage EMC filter for a motor controller of a new energy vehicle of the present invention; Figure 7 It is a schematic diagram of screw fastening on the top of the integrated multi-stage EMC filter for the motor controller of a new energy vehicle of the present invention; Figure 8 It is a schematic diagram of the screw fastening at the bottom of the integrated multi-stage EMC filter for the motor controller of a new energy vehicle according to the present invention. DETAILED DESCRIPTION

[0015] 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. Example

[0016] Please refer to the attached drawings of the specification. The technical problem to be solved in this embodiment is that the high current change rate di / dt and voltage change rate du / dt caused by the rapid switching of power semiconductor devices will inevitably generate electromagnetic noise, which will not only make the equipment itself unable to meet the EMC standard threshold requirements, but also affect other on-board equipment through the high-voltage power supply harness. Therefore, an integrated multi-stage EMC filter for a new energy vehicle motor controller is provided, and the integrated multi-stage EMC filter for a new energy vehicle motor controller includes: A filter housing 1 is provided with a magnetic ring through hole on the filter housing 1, and a runway-type primary magnetic ring 7 is fixedly installed in the lower part of the magnetic ring through hole 13. A positive copper bar assembly 4 and a negative copper bar assembly 3 are installed in parallel on the upper surface of the filter housing 1. One end of the positive copper bar assembly 4 and the negative copper bar assembly 3 passes through the runway-type primary magnetic ring 7. A primary filter circuit board 2 is installed at the end of the positive copper bar assembly 4 and the negative copper bar assembly 3. The primary filter circuit board 2 is provided with a primary filter circuit 21. A split secondary magnetic ring 8 is sleeved near the other end of the positive copper bar assembly 4 and the negative copper bar assembly 3. A side cover of the split secondary magnetic ring 8 away from the filter housing 1 is provided with a secondary magnetic ring pressing plate 5. The outer side of the secondary magnetic ring pressing plate 5 is surrounded by a secondary filter circuit board 6. A secondary filter circuit 61 is provided on the secondary filter circuit board 6. The primary filter circuit 21 and the secondary filter circuit 61 are connected to the positive and negative circuits of the positive copper bar assembly 4 and the negative copper bar assembly 3 through fastening screws.

[0017] The split secondary magnetic ring 8 includes a split ferrite magnetic ring upper half 51 and a split ferrite magnetic ring lower half 11. The filter housing 1 is provided with a magnetic ring installation groove 12. The split ferrite magnetic ring lower half 11 is fixedly connected to the magnetic ring installation groove 12 through a glue pouring process. The split ferrite magnetic ring upper half 51 is fixedly connected to the secondary magnetic ring pressing plate 5 through a glue pouring process. The split ferrite magnetic ring is made of manganese-zinc ferrite. The negative copper bar assembly 3 includes a first negative copper bar connection terminal 31, a second negative copper bar connection terminal 32, a negative copper bar connection copper column 33, a negative copper bar insulation plastic-dipped layer 34 and a negative copper bar 35. The first negative copper bar connection terminal 31 and the second negative copper bar connection terminal 32 are welded to the negative copper bar 35 at the same time. The negative copper bar connection copper column 33 and the negative copper bar 35 are interference connected. The negative copper bar insulation plastic-dipped layer 34 is sleeved on the negative copper bar 35.

[0018] The positive copper bar assembly 4 includes a first positive copper bar connection terminal 41, a second positive copper bar connection terminal 42, a positive copper bar connection copper column 43, a positive copper bar insulation plastic-dipped layer 44 and a positive copper bar 45. The first positive copper bar connection terminal 41 and the second positive copper bar connection terminal 42 are welded to the positive copper bar 45 at the same time. The positive copper bar connection copper column 43 and the positive copper bar 45 are interference connected. The positive copper bar insulation plastic-dipped layer 44 is sleeved on the positive copper bar 45.

[0019] The first-stage filter circuit board 2 is welded with a first negative filter common mode capacitor 211, a second negative filter common mode capacitor 212, a third negative filter common mode capacitor 213, a first positive filter common mode capacitor 214, a second positive filter common mode capacitor 215, a third positive filter common mode capacitor 216 and a first-stage filter differential mode capacitor 217 constituting the first-stage filter circuit 21; The capacitance values ​​of the first negative electrode filtering common mode capacitor 211, the second negative electrode filtering common mode capacitor 212 and the third negative electrode filtering common mode capacitor 213 are all 2.2 nF; The capacitance values ​​of the first positive filtering common mode capacitor 214, the second positive filtering common mode capacitor 215 and the third positive filtering common mode capacitor 216 are all 2.2 nF; The capacitance value of the first-stage filtering differential mode capacitor 217 is 33nF.

[0020] A fourth positive filter common mode capacitor 611, a secondary filter differential mode capacitor 612 and a fourth negative filter common mode capacitor 613 constituting a secondary filter circuit are welded on the secondary filter circuit board 6; The capacitance value of the fourth positive filtering common mode capacitor 611 is 100nF; The capacitance value of the fourth negative electrode filtering common mode capacitor 613 is 100nF; The capacitance value of the secondary filtering differential mode capacitor 612 is 6.8 nF.

[0021] The racetrack-shaped primary magnetic ring 7 is made of nanocrystalline material, and the racetrack-shaped primary magnetic ring 7 and the filter housing 1 are fixedly connected by glue injection.

[0022] Also includes a first fastening screw L1, a second fastening screw L2, a third fastening screw L3, a fourth fastening screw L4, a fifth fastening screw L5, a sixth fastening screw L6, a seventh fastening screw L7, an eighth fastening screw L8, a ninth fastening screw L9, a tenth fastening screw L10, an eleventh fastening screw L11, a twelfth fastening screw L12, a thirteenth fastening screw L13, a fourteenth fastening screw L14, a fifteenth fastening screw L15 and a sixteenth fastening screw L16; The first fastening screw L1 is used to fix and lock the primary filter circuit board and the first negative copper busbar connection terminal to the filter housing 1; The second fastening screw L2 is used to fix and lock the primary filter circuit board and the first positive copper busbar connection terminal to the filter housing 1; The third fastening screw L3 is used to fix and lock the negative copper busbar assembly and the negative electrode of the high-voltage DC busbar; The fourth fastening screw L4 is used to fix and lock the positive copper busbar assembly and the positive electrode of the high-voltage DC busbar; The fifth fastening screw L5 is used to fix and lock the primary filter circuit board to the controller housing for grounding; The sixth fastening screw L6 is used to fix and lock the second negative copper bar connection terminal and the primary filter circuit board to the filter housing 1; The seventh fastening screw L7 is used to fix and lock the primary filter circuit board to the controller housing for grounding; The eighth fastening screw L8 is used to fix and lock the secondary filter circuit board to the controller housing for grounding; The ninth fastening screw L9 is used to fix and lock the secondary magnetic ring pressing plate and the second positive copper bar connecting terminal to the filter housing 1; The tenth fastening screw L10 is used to fix and lock the secondary filter circuit board to the negative copper busbar connecting copper column 33. The eleventh fastening screw L11 is used to fix and lock the secondary filter circuit board onto the positive copper busbar connecting copper column 43; The twelfth fastening screw L12 is used to lock the filter housing 1 and the secondary magnetic ring pressure plate together on the motor controller housing; The thirteenth fastening screw L13 is used to fix and lock the secondary magnetic ring pressure plate to the filter housing 1; The fourteenth fastening screw L14 is used to lock the filter housing 1 and the motor controller housing, and is also used as a grounding point for the fourth positive filter common mode capacitor; The fifteenth fastening screw L15 and the sixteenth fastening screw L16 are used to fix and lock the filter output end to the subsequent DC-Link.

[0023] The specific connection methods of the primary filter circuit and the secondary filter circuit include: One end of the first positive filtering common mode capacitor 214 is electrically connected to the positive electrode of the DC high voltage bus, and the other end is grounded; One end of the second positive filtering common mode capacitor 215 is electrically connected to the positive electrode of the DC high voltage bus, and the other end is grounded; One end of the third positive filtering common mode capacitor 216 is electrically connected to the positive electrode of the DC high voltage bus, and the other end is grounded; One end of the first negative electrode filtering common mode capacitor 211 is electrically connected to the negative electrode of the DC high voltage bus, and the other end is grounded; One end of the second negative electrode filtering common mode capacitor 212 is electrically connected to the negative electrode of the DC high voltage bus, and the other end is grounded; One end of the third negative electrode filtering common mode capacitor 213 is electrically connected to the negative electrode of the DC high voltage bus, and the other end is grounded; One end of the primary filtering differential mode capacitor 217 is electrically connected to the positive electrode of the DC high voltage bus, and the other end is electrically connected to the negative electrode of the DC high voltage bus; One end of the secondary filtering differential mode capacitor 612 is electrically connected to the positive electrode of the DC high voltage bus, and the other end is electrically connected to the negative electrode of the DC high voltage bus; One end of the fourth negative electrode filtering common mode capacitor 613 is electrically connected to the negative electrode of the DC high voltage bus, and the other end is grounded; One end of the fourth positive filtering common mode capacitor 611 is electrically connected to the positive electrode of the DC high voltage bus, and the other end is grounded; A racetrack-type primary magnetic ring 7 is sleeved on the DC high-voltage busbar at the front end of the first positive filter common-mode capacitor 214 ; a split secondary magnetic ring 8 is also sleeved on the DC busbar between the primary filter differential-mode capacitor 217 and the secondary filter differential-mode capacitor 612 .

[0024] The implementation principle of this embodiment: The high-voltage DC bus is connected to the integrated multi-stage EMC filter through fixed connecting screws L3 and L4. The positive copper busbar assembly 4 and the negative copper busbar assembly 3 pass through the runway-type primary magnetic ring 7 made of nanocrystalline material. With its high magnetic permeability, wide frequency characteristics, high inductance and low loss, it can effectively suppress common-mode noise interference. The positive copper bar assembly 4 is connected to the primary filter circuit 21 through the first positive copper bar connection terminal 41 and the second positive copper bar connection terminal 42; the negative copper bar assembly 3 is connected to the primary filter circuit 21 through the first negative copper bar connection terminal 31 and the second negative copper bar connection terminal 32; the primary filter circuit board 2 is locked together with the first positive copper bar connection terminal 41, the second positive copper bar connection terminal 42, the first negative copper bar connection terminal 31 and the second negative copper bar connection terminal 32 on the filter housing 1 with fixed connection screws L1, L2, L6, L9; the positive filter common-mode capacitors 214, 215, 216 filter the positive circuit to suppress common-mode interference; the negative filter common-mode capacitors 211, 212, 213 filter the negative circuit to suppress common-mode interference; the primary filter differential-mode capacitor 217 is connected between the positive and negative circuits to suppress differential-mode interference. The fixing screw L5 locks the filter housing 1 to the motor controller housing, which not only fixes the filter but also serves as the grounding point for the negative filter common mode capacitors 211, 212, and 213. Similarly, the fixing screw L7 locks the filter housing 1 to the motor controller housing, which not only fixes the filter but also serves as the grounding point for the negative filter common mode capacitors 211, 212, and 213. The positive and negative copper busbar components further pass through the split secondary magnetic ring 8 made of Mn-Zn ferrite, which suppresses the high-frequency noise in the circuit with its high magnetic permeability. The fixing screws L9 and L13 lock the secondary magnetic ring pressure plate 5 to the filter housing 1, so that the upper and lower parts of the split secondary magnetic ring fit well. The fixing screws L10 and L11 are used to lock the secondary filter circuit board PCB 61 to the copper bars of the positive and negative copper bar assemblies 4 and 3, respectively, and the secondary filter differential mode capacitor 612 is placed between the two fixing screws L10 and L11 to connect the positive and negative poles of the circuit to suppress differential mode interference; the fourth positive filter common mode capacitor 611 and the fifth positive filter industrial mode capacitor 613 are arranged on both sides to suppress common mode interference of the positive and negative circuits; the fixing screw L14 is used to lock the filter to the motor controller housing, which not only plays the role of fixing the filter, but also can be used as the grounding point of the positive filter common mode capacitor 611; the fixing screw L8 is used to lock the lower right corner of the secondary filter circuit board 6 to the motor controller housing as a support, fixing and grounding point of the PCB. The fixing screw L12 is used to lock the filter housing 1 and the split secondary magnetic ring pressure plate 5 to the motor controller housing. The fixing screws L15 and L16 are used.

[0025] The filter output is connected to the subsequent DC-Link by locking.

[0026] In the description of the present invention, it is necessary to understand that the terms "coaxial", "bottom", "one end", "top", "middle", "the other end", "upper", "one side", "top", "inside", "front", "center", "both ends" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present invention.

[0027] In the present invention, unless otherwise clearly stipulated and limited, the terms such as "installation", "setting", "connection", "fixation" and "screw-on" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral one; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal connection of two elements or the interaction relationship between two elements. Unless otherwise clearly defined, ordinary technicians in this field can understand the specific meanings of the above terms in the present invention according to the specific circumstances.

[0028] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. An integrated multi-stage EMC filter for a new energy vehicle motor controller, characterized in that: include: A filter housing, wherein a magnetic ring through hole is provided on the filter housing, a runway-type primary magnetic ring is fixedly installed in the lower part of the magnetic ring through hole, a positive copper bar assembly and a negative copper bar assembly are installed in parallel on the upper surface of the filter housing, one end of the positive copper bar assembly and the negative copper bar assembly pass through the runway-type primary magnetic ring, a primary filter circuit board is installed at the end of the positive copper bar assembly and the negative copper bar assembly, the primary filter circuit board is provided with a primary filter circuit, the positive copper bar assembly and the negative copper bar assembly are sleeved with a split secondary magnetic ring near the other end, a side cover of the split secondary magnetic ring away from the filter housing is provided with a secondary magnetic ring pressure plate, the outer side of the secondary magnetic ring pressure plate is surrounded by a secondary filter circuit board, a secondary filter circuit is provided on the secondary filter circuit board, the primary filter circuit board is provided with a secondary filter circuit, the primary filter circuit and the secondary filter circuit are connected to the positive copper bar assembly and the negative copper bar assembly for positive and negative circuits through fastening screws.

2. The integrated multi-stage EMC filter for the motor controller of a new energy vehicle according to claim 1, characterized in that: The split secondary magnetic ring includes a split ferrite magnetic ring upper half and a split ferrite magnetic ring lower half. A magnetic ring mounting groove is opened on the filter housing. The split ferrite magnetic ring lower half is fixedly connected to the magnetic ring mounting groove through a glue pouring process. The split ferrite magnetic ring upper half is fixedly connected to the secondary magnetic ring pressure plate through a glue pouring process.

3. The integrated multi-stage EMC filter for the motor controller of a new energy vehicle according to claim 2, characterized in that: The negative copper bar assembly comprises a first negative copper bar connecting terminal, a second negative copper bar connecting terminal, a negative copper bar connecting copper column, a negative copper bar insulating plastic-dipped layer and a negative copper bar. The first negative copper bar connecting terminal and the second negative copper bar connecting terminal are welded to the negative copper bar at the same time. The negative copper bar connecting copper column and the negative copper bar are interference-connected. The negative copper bar insulating plastic-dipped layer is sleeved on the negative copper bar.

4. The integrated multi-stage EMC filter for the motor controller of a new energy vehicle according to claim 3, characterized in that: The positive copper bar assembly comprises a first positive copper bar connection terminal, a second positive copper bar connection terminal, a positive copper bar connection copper column, a positive copper bar insulation plastic-dip layer and a positive copper bar. The first positive copper bar connection terminal and the second positive copper bar connection terminal are welded to the positive copper bar at the same time. The positive copper bar connection copper column and the positive copper bar are interference-connected. The positive copper bar insulation plastic-dip layer is sleeved on the positive copper bar.

5. The integrated multi-stage EMC filter for the motor controller of a new energy vehicle according to claim 4, characterized in that: The first-level filter circuit board is welded with a first negative filter common mode capacitor, a second negative filter common mode capacitor, a third negative filter common mode capacitor, a first positive filter common mode capacitor, a second positive filter common mode capacitor, a third positive filter common mode capacitor and a first-level filter differential mode capacitor constituting a first-level filter circuit; The capacitance values ​​of the first negative electrode filtering common mode capacitor, the second negative electrode filtering common mode capacitor and the third negative electrode filtering common mode capacitor are all 2.2 nF; The capacitance values ​​of the first positive electrode filtering common mode capacitor, the second positive electrode filtering common mode capacitor and the third positive electrode filtering common mode capacitor are all 2.2 nF; The capacitance value of the first-stage filtering differential mode capacitor is 33nF.

6. The integrated multi-stage EMC filter for the motor controller of a new energy vehicle according to claim 5, characterized in that: The secondary filter circuit board is welded with a fourth positive filter common mode capacitor, a secondary filter differential mode capacitor and a fourth negative filter common mode capacitor constituting a secondary filter circuit; The capacitance value of the fourth positive electrode filtering common mode capacitor is 100nF; The capacitance value of the fourth negative electrode filtering common mode capacitor is 100nF; The capacitance value of the secondary filtering differential mode capacitor is 6.8 nF.

7. The integrated multi-stage EMC filter for the motor controller of a new energy vehicle according to claim 6, characterized in that: The racetrack-shaped primary magnetic ring is made of nanocrystalline material, and the racetrack-shaped primary magnetic ring and the filter housing are fixedly connected by glue injection.

8. The integrated multi-stage EMC filter for the motor controller of a new energy vehicle according to claim 7, characterized in that: Also includes a first fastening screw, a second fastening screw, a third fastening screw, a fourth fastening screw, a fifth fastening screw, a sixth fastening screw, a seventh fastening screw, an eighth fastening screw, a ninth fastening screw, a tenth fastening screw, an eleventh fastening screw, a twelfth fastening screw, a thirteenth fastening screw, a fourteenth fastening screw, a fifteenth fastening screw and a sixteenth fastening screw; The first fastening screw is used to fix and lock the primary filter circuit board and the first negative copper busbar connection terminal to the filter housing; The second fastening screw is used to fix and lock the primary filter circuit board and the first positive copper busbar connection terminal to the filter housing; The third fastening screw is used to fix and lock the negative copper busbar assembly and the negative electrode of the high-voltage DC busbar; The fourth fastening screw is used to fix and lock the positive copper busbar assembly and the positive electrode of the high-voltage DC busbar; The fifth fastening screw is used to fix and lock the primary filter circuit board to the controller housing for grounding; The sixth fastening screw is used to fix and lock the second negative copper bar connecting terminal and the primary filter circuit board to the filter housing; The seventh fastening screw is used to fix and lock the primary filter circuit board to the controller housing for grounding; The eighth fastening screw is used to fix and lock the secondary filter circuit board to the controller housing for grounding; The ninth fastening screw is used to fix and lock the secondary magnetic ring pressing plate and the second positive copper bar connecting terminal to the filter housing; The tenth fastening screw is used to fix and lock the secondary filter circuit board onto the negative copper busbar connecting copper column. The eleventh fastening screw is used to fix and lock the secondary filter circuit board onto the positive copper busbar connecting copper column; The twelfth fastening screw is used to lock the filter housing and the secondary magnetic ring pressure plate together on the motor controller housing; The thirteenth fastening screw is used to fix and lock the secondary magnetic ring pressure plate to the filter housing; The fourteenth fastening screw is used to lock the filter housing and the motor controller housing, and is also used as a grounding point for the fourth positive filter common mode capacitor; The fifteenth fastening screw and the sixteenth fastening screw are used to fix and lock the filter output end to the subsequent DC-Link.

9. The integrated multi-stage EMC filter for the motor controller of a new energy vehicle according to claim 8, characterized in that: The specific connection method of the primary filter circuit and the secondary filter circuit includes: One end of the first positive filtering common-mode capacitor is electrically connected to the positive electrode of the DC high-voltage bus, and the other end is grounded; One end of the second positive filter common mode capacitor is electrically connected to the positive electrode of the DC high voltage bus, and the other end is grounded; One end of the third positive filtering common mode capacitor is electrically connected to the positive electrode of the DC high voltage bus, and the other end is grounded; One end of the first negative electrode filtering common mode capacitor is electrically connected to the negative electrode of the DC high voltage bus, and the other end is grounded; One end of the second negative electrode filtering common mode capacitor is electrically connected to the negative electrode of the DC high voltage bus, and the other end is grounded; One end of the third negative electrode filtering common mode capacitor is electrically connected to the negative electrode of the DC high voltage bus, and the other end is grounded; One end of the primary filtering differential mode capacitor is electrically connected to the positive electrode of the DC high voltage bus, and the other end is electrically connected to the negative electrode of the DC high voltage bus; One end of the secondary filtering differential mode capacitor is electrically connected to the positive electrode of the DC high voltage bus, and the other end is electrically connected to the negative electrode of the DC high voltage bus; One end of the fourth negative electrode filtering common mode capacitor is electrically connected to the negative electrode of the DC high voltage bus, and the other end is grounded; One end of the fourth positive filtering common mode capacitor is electrically connected to the positive electrode of the DC high voltage bus, and the other end is grounded; A racetrack-type primary magnetic ring is sleeved on the DC high-voltage busbar at the front end of the first positive filter common-mode capacitor; a split secondary magnetic ring is also sleeved on the DC busbar between the primary filter differential-mode capacitor and the secondary filter differential-mode capacitor.

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