Motor controller and motor control system

Abstract

The invention relates to the technical field of new energy vehicle motor controllers, in particular to a motor controller and a motor control system. The motor controller comprises a capacitor unit, a power unit, a driving unit, a control unit and a built-in shell; the capacitor unit is encapsulated in the built-in shell; the power unit and the driving unit are integrated on a power substrate assembly, and the power substrate assembly is fixed to the outer side of the built-in shell and electrically connected with the capacitor unit. The control unit is integrated on a control substrate, and the control substrate is electrically connected with the power substrate assembly. According to the motor controller and the motor control system, the problems that all parts of a traditional motor controller are independently packaged, the size and weight are large, the power density is low, the cost is high, and the requirement of a high-performance whole vehicle cannot be met are solved.

Description

Technical Field

[0001] The present application relates to the technical field of motor controllers for new energy vehicles, and in particular to a motor controller and a motor control system. Background Art

[0002] The technical trend of new energy vehicle motor controllers is high performance, high power density, and low cost. At present, 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 and the cost is low.

[0003] The conventional circuit of the motor controller of a new energy vehicle consists of a bus capacitor, a power module, a drive unit, a control unit and a discharge unit 7. The DC voltage of the high-voltage battery 6 smoothes the ripple through the bus capacitor, and is chopped into a three-phase sine wave through the three-phase six-switch power module to drive the motor to rotate. Among them, the control signal of the three-phase switch power module is generated in the control unit, and after the power amplification of the drive unit, it finally drives the power switch, 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.

[0004] However, the traditional power module is an independent packaging form, and the packaging forms include plastic packaging and frame type. The drive unit is also an independent packaging form, and the packaging form is a PCB board-mounted form, and the connection method with the power module is soldering and bolt connection. The control unit is also an independent packaging form, and the packaging form is a PCB board-mounted form, and it is connected to the drive unit through a cable. The busbar capacitor is also an independent packaging form, and the packaging form is plastic packaging, and it is connected to the power module through bolts. The filter unit and the discharge unit 7 are also independent packaging forms, and are also bolted.

[0005] However, each component of a traditional motor controller is packaged independently, which is large in size and weight, has low power density and high cost, and can no longer meet the needs of high-performance vehicles. Summary of the invention

[0006] The purpose of this application is to provide a motor controller and a motor control system, thereby solving the problem that various components of a traditional motor controller are independently packaged, have large size and weight, low power density, high cost, and cannot meet the needs of high-performance vehicles.

[0007] According to the first aspect of the present application, a motor controller is provided, which includes a capacitor unit, a power unit, a drive unit, a control unit and a built-in shell; the capacitor unit is encapsulated inside the built-in shell; the power unit and the drive unit are integrated on a power substrate assembly, the power substrate assembly is fixed to the outside of the built-in shell and is electrically connected to the capacitor unit; the control unit is integrated on a control substrate, and the control substrate is electrically connected to the power substrate assembly.

[0008] In any of the above technical solutions, further, the motor controller also includes a filter unit and a power terminal block; the filter unit includes a filter core; the capacitor unit includes a capacitor core; the capacitor core and the filter core are both encapsulated inside the built-in shell to form a capacitor filter assembly with the built-in shell; the power terminal block is arranged outside the capacitor filter assembly and is electrically connected to the capacitor filter assembly.

[0009] In any of the above technical solutions, further, the inner cavity of the built-in shell is provided with a cooling water channel to dissipate heat for the capacitor unit, the filter unit and the power substrate assembly; and / or, the built-in shell is provided with a water outlet and a water inlet connected to the cooling water channel, and the water outlet, the water inlet, the power terminal block and the filter core are all located on the same side of the capacitor filter assembly.

[0010] In any of the above technical solutions, further, the motor controller also includes a shielding plate; the built-in shell is a slot structure or a hollow structure, an opening is provided on one side of the built-in shell, the shielding plate covers the opening, and the shielding plate is provided between the opening and the control substrate.

[0011] In any of the above technical solutions, further, the motor controller also includes an external shell, a water inlet pipe, a water outlet pipe and a low-voltage terminal block; the low-voltage terminal block supplies power to the control substrate; the external shell is cylindrical, and the external shell includes an upper cover, a bottom cover and a side wall; the power substrate assembly, the capacitor filter assembly, the shielding plate and the control substrate are all arranged inside the external shell; the capacitor filter assembly is fixedly connected to the bottom cover; the water inlet pipe and the water outlet pipe are respectively connected to the water inlet and water outlet of the built-in shell, and the water inlet pipe, the water outlet pipe, the low-voltage terminal block and the power terminal block are all fixed to the side wall.

[0012] In any of the above technical solutions, further, the power terminal block is laser welded to the capacitor filter assembly via a copper busbar; the capacitor filter assembly is laser welded to the power substrate assembly via a copper busbar; and the power substrate assembly is welded to the control substrate.

[0013] In any of the above technical solutions, further, there are three power substrate assemblies, namely, a U-phase power substrate assembly, a V-phase power substrate assembly and a W-phase power substrate assembly; each of the power substrate assemblies includes a drive circuit board located on the upper layer and a power circuit board located on the lower layer; the drive circuit board includes a low-voltage connector, an electronic device and a discharge device located on the first layer, a first insulating layer located on the second layer, and a welding copper layer, a positive power terminal and a three-phase output power terminal located on the third layer; wherein the low-voltage connector is electrically connected to the control substrate; the power circuit board includes a second insulating layer located on the fourth layer, an upper copper layer located on the fifth layer, a third insulating layer located on the sixth and seventh layers, a negative power terminal and a lower copper layer located on the eighth layer, and an insulating thermal conductive layer located on the ninth layer; wherein the third insulating layer is embedded with a semiconductor chip; wherein the lower copper layer and the upper copper layer are connected to the semiconductor chip through copper plating via holes; wherein the negative power terminal and the positive power terminal are electrically connected to the capacitor filter assembly.

[0014] In any of the above technical solutions, further, there are multiple semiconductor chips.

[0015] In any of the above technical solutions, further, the motor controller also includes a hollow shell; the external shell and the hollow shell are both cylindrical; the capacitor filter assembly, the shielding plate, the control substrate, the upper cover and the bottom cover are all provided with through holes for installing the hollow shell.

[0016] According to a second aspect of the present application, a motor control system is provided, the motor control system comprising the motor controller as described above.

[0017] In any of the above technical solutions, further, the motor includes a motor body and an output shaft, and the output shaft is installed in the hollow shell.

[0018] The motor controller of the present application includes a capacitor unit, a power unit, a drive unit, a control unit and a built-in shell. The capacitor unit is encapsulated inside the built-in shell; the power unit and the drive unit are integrated on a power substrate assembly, which is fixed to the outside of the built-in shell and electrically connected to the capacitor unit; the control unit is integrated on a control substrate, which is electrically connected to the power substrate assembly.

[0019] According to the above technical features, the beneficial effects of this application are:

[0020] The present application integrates the power unit and the drive unit through the power substrate assembly, integrates the control unit through the control substrate, and the power substrate assembly is fixed to the outside of the built-in housing, and is directly electrically connected to the capacitor unit and the control substrate encapsulated inside the built-in housing. Compared with the prior art (each component of the existing motor controller is in an independent packaging form, and each component includes a housing connected by bolts), the high integration of the present application makes the overall volume and weight of the motor controller lower, which can achieve high power density, low cost, improve vehicle carrying capacity, and meet the needs of high-performance vehicles.

[0021] In order to make the above-mentioned objects, features and advantages of the present application more obvious and easy to understand, preferred embodiments are specifically cited below and described in detail with reference to the attached drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings required for use in the embodiments will be briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present application 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 paying creative work.

[0023] Figure 1 A schematic diagram showing an exploded structure of a motor controller according to an embodiment of the present application is shown;

[0024] Figure 2 A front view showing a motor controller according to an embodiment of the present application;

[0025] Figure 3 A side view of a power baseboard assembly according to an embodiment of the present application is shown;

[0026] Figure 4 A schematic diagram showing the assembly structure of a motor and a motor controller according to an embodiment of the present application;

[0027] Figure 5 An exemplary circuit diagram of a power topology of a motor controller according to an embodiment of the present application is shown.

[0028] Icons: 100-power substrate assembly; 110-driver circuit board; 111-components; 112-welding copper layer; 113-low-voltage connector; 114-first insulation layer; 120-power circuit board; 115-positive power terminal; 126-three-phase output power terminal; 121-upper copper layer; 122-via copper plating; 123-semiconductor chip; 124-negative power terminal; 125-second insulation layer; 127-insulating thermal conductive layer; 128-third upper insulation layer; 129-third lower Insulation layer; 130-lower copper layer; 200-capacitor filter assembly; 210-capacitor core; 220-filter core; 230-built-in housing; 300-hollow housing; 400-power terminal block; 500-low-voltage terminal block; 610-water inlet pipe; 620-water outlet pipe; 700-three-phase copper busbar; 800-external housing; 810-upper cover; 820-bottom cover; 830-side wall; 900-motor body; 910-output shaft; 1100-control substrate; 1200-shielding plate;

[0029] 1-drive unit; 2-power unit; 3-capacitor unit; 4-control unit; 5-motor; 6-high-voltage battery; 7-discharge unit. DETAILED DESCRIPTION

[0030] The following specific embodiments are provided to help the reader obtain a comprehensive understanding of the methods, devices and / or systems described herein. However, after understanding the disclosure of the present application, various changes, modifications and equivalents of the methods, devices and / or systems described herein will be apparent. For example, the order of operations described herein is merely an example, and is not limited to the order set forth herein, but in addition to the operations that must occur in a particular order, changes that will be apparent after understanding the disclosure of the present application may be made. In addition, in order to improve clarity and brevity, descriptions of features known in the art may be omitted.

[0031] The features described herein may be implemented in different forms and should not be interpreted as being limited to the examples described herein. Rather, the examples described herein have been provided only to illustrate some of the many possible ways of implementing the methods, devices and / or systems described herein that will be apparent after understanding the disclosure of the present application.

[0032] Throughout the specification, when an element (such as a layer, a region, or a substrate) is described as being “on”, “connected to”, “bound to”, “over”, or “covering” another element, it may be directly “on”, “connected to”, “bound to”, “over”, or “covering” another element, or one or more other elements may be present between them. In contrast, when an element is described as being “directly on”, “directly connected to”, “directly bound to”, “directly over”, or “directly covering” another element, there may be no other elements present between them.

[0033] As used herein, the term "and / or" includes any one of the associated listed items and any combination of any two or more items.

[0034] Although terms such as "first," "second," and "third" may be used herein to describe various members, components, regions, layers, or portions, these members, components, regions, layers, or portions are not limited by these terms. Rather, these terms are only used to distinguish one member, component, region, layer, or portion from another member, component, region, layer, or portion. Therefore, without departing from the teachings of the examples described herein, the first member, component, region, layer, or portion referred to may also be referred to as the second member, component, region, layer, or portion.

[0035] For ease of description, spatial relational terms such as "above", "upper", "below", and "lower" may be used herein to describe the relationship of one element to another element as shown in the accompanying drawings. Such spatial relational terms are intended to include different orientations of the device in use or operation in addition to the orientation depicted in the accompanying drawings. For example, if the device in the accompanying drawings is turned over, an element described as being "above" or "upper" relative to another element will subsequently be "below" or "lower" relative to the other element. Therefore, the term "above" includes both "above" and "below" orientations depending on the spatial orientation of the device. The device may also be positioned in other ways (e.g., rotated 90 degrees or in other orientations), and the spatial relational terms used herein will be interpreted accordingly.

[0036] The terms used herein are only used to describe various examples and are not used to limit the present disclosure. Unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. The terms "include", "comprise" and "have" list the stated features, quantities, operations, components, elements and / or their combinations that exist, but do not exclude the existence or addition of one or more other features, quantities, operations, components, elements and / or their combinations.

[0037] Variations in the shapes shown in the drawings may occur due to manufacturing techniques and / or tolerances. Therefore, the examples described herein are not limited to the specific shapes shown in the drawings but include variations in shapes that occur during manufacturing.

[0038] The features of the examples described herein can be combined in various ways that will be apparent after understanding the disclosure of the present application. In addition, although the examples described herein have various configurations, other configurations are possible as will be apparent after understanding the disclosure of the present application.

[0039] In the embodiments of the present application, Figure 5 As shown, the motor controller of the present application includes a capacitor unit 3, a filter unit, a power unit 2, a drive unit 1, a control unit 4 and a discharge unit 7. Among them, the DC voltage of the high-voltage battery 6 passes through the filter unit, the ripple is smoothed by the capacitor unit 3, and the three-phase six-switch power unit 2 is chopped into a three-phase sine wave to drive the motor to rotate. Among them, the control signal of the three-phase switch power unit 2 is generated by the control unit 4, and after the power amplification of the drive unit 1, it finally drives the power switch, 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 new energy vehicle to operate.

[0040] Before the present application was proposed, the traditional power unit was an independent packaging form, and the packaging forms included plastic packaging and frame type. The drive unit was also an independent packaging form, and the packaging form was a PCB board-mounted form, and the connection method with the power unit was soldering and bolt connection. The control unit was also an independent packaging form, and the packaging form was a PCB board-mounted form, and it was connected to the drive unit 1 through a wiring harness. The capacitor unit was also an independent packaging form, and the packaging form was plastic packaging, and it was connected to the power unit through bolts. The filter unit and the discharge unit were also independent packaging forms, and were also bolted. However, the various components of the traditional motor controller are all independent packaging forms, which are large in size and weight, low in power density, and high in cost, and can no longer meet the needs of high-performance vehicles.

[0041] In view of this, the first aspect of the present application provides a motor controller to solve the above technical problems. Figures 1 to 5 A motor controller according to some embodiments of the present application is described.

[0042] like Figure 1 and Figure 2 As shown, the motor controller of the present application includes a capacitor unit 3, a filter unit, a power unit 2, a drive unit 1, a control unit 4 and a built-in housing 230. The filter unit and the capacitor unit 3 are encapsulated inside the built-in housing 230; the power unit 2 and the drive unit 1 are integrated on the power substrate assembly 100, the power substrate assembly 100 is fixed to the outside of the built-in housing 230, and is electrically connected to the filter unit and the capacitor unit 3; the control unit 4 is integrated on the control substrate 1100, and the control substrate 1100 is electrically connected to the power substrate assembly 100.

[0043] The present application integrates the power unit 2 and the drive unit 1 through the power substrate assembly 100, integrates the control unit 4 through the control substrate 1100, and the power substrate assembly 100 is fixed to the outside of the built-in housing 230, and is directly electrically connected to the capacitor unit 3 and the filter unit encapsulated inside the built-in housing 230, and the control substrate 1100. Compared with the prior art (each component of the existing motor controller is in an independent packaging form, and each component includes a housing connected by bolts), the high integration of the present application makes the overall volume and weight of the motor controller lower, which can achieve high power density, low cost, improve vehicle carrying capacity, and meet the needs of high-performance vehicles.

[0044] In the embodiments of the present application, Figure 2 As shown, the filter unit includes a plurality of filter cores 220, and the capacitor unit 3 includes a plurality of capacitor cores 210. The built-in housing 230 is a slot structure or a hollow structure, and the plurality of capacitor cores 210 and the plurality of filter cores 220 are integrally potted in the slot structure or the hollow structure by resin to form a capacitor filter assembly 200 with the slot structure or the hollow structure.

[0045] Furthermore, if Figure 2 As shown, the inner cavity of the built-in housing 230 is provided with a cooling water channel to dissipate heat for the capacitor unit 3 (a plurality of capacitor cores 210 ), the filter unit (a plurality of filter cores 220 ) and the power substrate assembly 100 .

[0046] Furthermore, if Figure 2 As shown, the motor controller of the present application also includes a power wiring seat 400, which is arranged outside the capacitor filter assembly 200. The built-in housing 230 is provided with a water outlet and a water inlet connected to the cooling water channel, and the water outlet, the water inlet, the power wiring seat 400 and the filter core 220 are all located on the same side of the capacitor filter assembly 200. In this way, the filter core needs to be arranged next to the power wiring seat 400, so as to facilitate the electrical connection between the power wiring seat 400 and the capacitor filter assembly 200 (filter core 220).

[0047] Preferably, a copper busbar extending from the filter core 220 may be provided on the top of the built-in housing 230 of the capacitor filter assembly 200 , and the power terminal block 400 is directly laser welded to the capacitor filter assembly 200 via the copper busbar.

[0048] Further, in the embodiments of the present application, Figure 1 As shown, the motor controller also includes a shielding plate 1200. An opening is provided on one side of the built-in housing 230, and the shielding plate 1200 is covered on the opening, and the shielding plate 1200 is arranged between the opening and the control substrate 1100. The shielding plate 1200 is arranged between the control substrate 1100 and the capacitor filter assembly 200, which can shield high and low voltage signals and improve electromagnetic compatibility performance. In addition, the shielding plate 1200 does not seal the opening on one side of the built-in housing 230, for example, space for copper busbar arrangement can be reserved.

[0049] Further, in the embodiments of the present application, Figure 1 and Figure 2 As shown, the motor controller also includes an external housing 800, a water inlet pipe 610, a water outlet pipe 620 and a low-voltage wiring socket 500. Among them, the low-voltage wiring socket 500 supplies power to the control substrate 1100; the external housing 800 is cylindrical, and the external housing 800 includes an upper cover 810, a bottom cover 820 and a side wall 830; the power substrate assembly 100, the capacitor filter assembly 200, the shielding plate 1200 and the control substrate 1100 are all arranged inside the external housing 800. The capacitor filter assembly 200 is fixedly welded to the bottom cover 820, the water inlet pipe 610 and the water outlet pipe 620 are respectively connected to the water inlet and the water outlet of the internal housing 230, and the water inlet pipe 610, the water outlet pipe 620, the low-voltage wiring socket 500 and the power wiring socket 400 are all fixed to the side wall 830.

[0050] In the embodiments of the present application, Figure 2 and Figure 3 As shown, the power substrate assembly 100 is composed of a three-phase full bridge, and there are three power substrate assemblies 100, namely, the U-phase power substrate assembly, the V-phase power substrate assembly, and the W-phase power substrate assembly. The three power substrate assemblies 100 are arranged on the outer wall of the capacitor filter assembly 200, and the three power substrate assemblies 100 can be placed on the side, top, and bottom of the capacitor filter assembly 200, and can be selected according to the layout space of the whole vehicle. In addition, the three power substrate assemblies 100 can be soldered or silver sintered, so that the heat dissipation efficiency of the built-in cooling water channel of the built-in shell 230 for the power substrate assembly 100 can be increased.

[0051] In addition, the capacitor filter assembly 200 of the present application is laser welded to the power substrate assembly 100 via a copper busbar. For example, the top of the built-in housing 230 of the capacitor filter assembly 200 may be provided with a copper busbar extending from the capacitor core 210, and the power substrate assembly 100 is directly laser welded to the capacitor filter assembly 200 via the copper busbar.

[0052] See below for Figure 3 The specific structure of the power substrate assembly 100 is described.

[0053] The power substrate assembly 100 has power chips (MOS / IGBT) embedded in the middle layer, drive circuits arranged on the upper layer, and power circuits arranged on the lower layer. Figure 3 As shown, each power substrate assembly 100 includes a driving circuit board 110 located at an upper layer and a power circuit board 120 located at a lower layer.

[0054] The driving circuit board 110 is a common multi-layer FR4 circuit board. The driving circuit board 110 includes components 111 located on the first layer, including multiple electronic devices and discharge units, such as driving chips, capacitors, resistors, transformers, etc. In addition, the driving circuit board 110 includes a low-voltage connector 113 located on the first layer, wherein the low-voltage connector 113 is electrically connected to the control substrate 1100 (for example, directly welded), and the control substrate 1100 provides power and signal transmission for the driving circuit board 110. The driving circuit board 110 includes a first insulating layer 114 located on the second layer (the first insulating layer 114 is, for example, a FR4 insulating layer) and a soldering copper layer 112, a forward power terminal 115, and a three-phase output power terminal 126 located on the third layer.

[0055] The power circuit board 120 is a circuit board in which a semiconductor chip 123 is embedded. The power circuit board 120 includes a second insulating layer 125 located on the fourth layer (the second insulating layer 125 insulates the power circuit board 120 from the driving circuit board 110), an upper copper layer 121 located on the fifth layer, and a third upper insulating layer 128 and a third lower insulating layer 129 located on the sixth and seventh layers. The power circuit board 120 also includes a negative power terminal 124 and a lower copper layer 130 located on the eighth layer, and an insulating heat-conducting layer 127 located on the ninth layer.

[0056] Furthermore, the third insulating PP layer composed of the third upper insulating layer 128 and the third lower insulating layer 129 is embedded in the semiconductor chip 123 (MOS / IGBT), and the lower copper layer 130 and the upper copper layer 121 are connected to the semiconductor chip 123 (power chip) through the via copper plating 122. It should be noted that, Figure 5 The figure shows the form of a three-phase six-switch power module (IGBT chip). Figure 3The form of two power chips is shown in the figure. In this embodiment, the number of semiconductor chips 123 can be multiple, and the specific number can be buried in the third insulating PP layer according to the needs. In this way, the form of power chip integration has lower stray parameters and is more convenient to achieve stepless power expansion, thereby achieving high performance (in the prior art, the housing space of the shell is limited, the power chip cannot be expanded, and the power chip is affected by external connectors, and the stray parameters are high).

[0057] In addition, the negative power terminal 124 and the positive power terminal 115 are laser welded to the capacitor filter assembly 200 through a copper bar. Figure 1 and Figure 2 As shown, the three three-phase output power terminals 126 of the three power substrate assemblies 100 are output through the three-phase copper busbar 700. The three-phase copper busbar 700 can be arranged on the bottom cover 820 of the external housing 800, extending out of the bottom cover 820, and connected to the three phases of the motor.

[0058] Further, in the embodiments of the present application, Figure 1 and Figure 2 As shown, the motor controller further includes a hollow housing 300. The external housing 800 and the hollow housing 300 are both cylindrical; the capacitor filter assembly 200, the shielding plate 1200, the control substrate 1100, the upper cover 810 and the bottom cover 820 are all provided with through holes for installing the hollow housing 300. When the motor 5 is assembled with the motor controller, as shown in FIG. Figure 3 As shown, after the hollow housing 300 is assembled through the through holes of the capacitor filter assembly 200 , the shielding plate 1200 , the control substrate 1100 , the upper cover 810 and the bottom cover 820 , the output shaft 910 of the motor 5 is then installed in the hollow housing 300 .

[0059] In this arrangement, the motor controller is installed in the same direction as the output shaft of the motor 5, which reduces the surface area and volume of the motor 5 controller, making it easier to carry the whole vehicle. Moreover, the external housing 800 and the hollow housing 300 are both cylindrical and designed to mimic the output shaft 910 of the motor 5, subverting the regular rectangular shape of the film capacitor. The annular cylindrical structure is easier to integrate with the motor 5 in the axial direction, forming a whole, and making it easier to carry.

[0060] According to a second aspect of the present application, a motor control system is provided, the motor control system comprising a motor and the above motor controller. The motor comprises a motor body 900 and an output shaft 910 , and the output shaft 910 is mounted on a hollow housing 300 .

[0061] With this configuration, when the new energy vehicle motor and motor controller are assembled, Figure 3As shown, after the hollow shell 300 is assembled through the through holes of the capacitor filter assembly 200, the shielding plate 1200, the control substrate 1100, the upper cover 810 and the bottom cover 820, the output shaft 910 of the motor is then installed in the hollow shell 300. In this way, the motor controller is installed axially with the motor, which reduces the surface area and volume of the motor controller, making it easier to carry the whole vehicle. Moreover, both the external shell 800 and the hollow shell 300 are cylindrical and designed to imitate the motor output shaft 910, subverting the regular rectangular shape of the thin film capacitor. The annular cylindrical structure is conducive to integration with the axial direction of the motor to form a whole, which is more portable.

[0062] In summary, the high-power density motor controller of the present application integrates power chips, drive units, discharge units, etc. through PCB boards, subverts the regular rectangular shape of thin-film capacitors, designs ring capacitors, and integrates them with electromagnetic filters. The ring structure is conducive to integration with the axial direction of the motor. The power substrate assembly can be placed on the side, top, and bottom of the capacitor, and the best choice can be made according to the layout space of the whole vehicle. In addition, this high-power density motor controller 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. In addition, the original method of producing independent components in various places and then bolting them together in the general assembly plant is complex and has high transportation costs. This application can be concentrated in one place for production, simplifying the production process, and lowering material costs. The motor controller is installed axially with the motor, reducing the surface area and volume of the motor controller, which is more conducive to vehicle carrying.

[0063] Finally, it should be noted that the above-described embodiments are only specific implementation methods of the present application, which are used to illustrate the technical solutions of the present application rather than to limit them. The protection scope of the present application is not limited thereto. Although the present application has been described in detail with reference to the aforementioned embodiments, ordinary technicians in this field should understand that any technician familiar with this technical field can still modify the technical solutions recorded in the aforementioned embodiments within the technical scope disclosed in the present application, or make equivalent replacements for some of the technical features therein; and these modifications, changes or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present application, and should all be covered by the protection scope of the present application.

Claims

1. A motor controller, characterized in that: The motor controller includes a capacitor unit, a power unit, a drive unit, a control unit and a built-in housing; The capacitor unit is encapsulated inside the built-in housing; The power unit and the drive unit are integrated on a power substrate assembly, and the power substrate assembly is fixed to the outside of the built-in housing and electrically connected to the capacitor unit; The control unit is integrated on a control substrate, and the control substrate is electrically connected to the power substrate assembly.

2. The motor controller according to claim 1, characterized in that: The motor controller also includes a filter unit and a power wiring socket; The filter unit includes a filter core; the capacitor unit includes a capacitor core; The capacitor core and the filter core are both encapsulated inside the built-in housing to form a capacitor filter assembly with the built-in housing; The power connection seat is arranged outside the capacitor filter assembly and is electrically connected to the capacitor filter assembly.

3. The motor controller according to claim 2, characterized in that: The inner cavity of the built-in housing is provided with a cooling water channel to dissipate heat for the capacitor unit, the filter unit and the power substrate assembly; And / or, the built-in shell is provided with a water outlet and a water inlet communicated with the cooling water channel, and the water outlet, the water inlet, the power wiring socket and the filter core are all located on the same side of the capacitor filter assembly.

4. The motor controller according to claim 2, characterized in that: The motor controller also includes a shielding plate; The built-in housing is a slot structure or a hollow structure. An opening is arranged on one side of the built-in housing. The shielding plate covers the opening. The shielding plate is arranged between the opening and the control substrate.

5. The motor controller according to claim 4, characterized in that: The motor controller also includes an external housing, a water inlet pipe, a water outlet pipe and a low-voltage wiring socket; The low voltage wiring socket supplies power to the control substrate; The external shell is cylindrical and comprises an upper cover, a bottom cover and a side wall; The power substrate assembly, the capacitor filter assembly, the shielding plate and the control substrate are all arranged inside the external housing; The capacitor filter assembly is fixedly connected to the bottom cover; The water inlet pipe and the water outlet pipe are respectively connected to the water inlet and the water outlet of the built-in shell, and the water inlet pipe, the water outlet pipe, the low-voltage wiring socket and the power wiring socket are all fixed to the side wall.

6. The motor controller according to claim 2, characterized in that: The power wiring seat is laser welded to the capacitor filter assembly via a copper busbar; the capacitor filter assembly is laser welded to the power substrate assembly via a copper busbar; and the power substrate assembly is welded to the control substrate.

7. The motor controller according to claim 2, characterized in that: The power substrate assembly is divided into three parts, namely, a U-phase power substrate assembly, a V-phase power substrate assembly and a W-phase power substrate assembly; Each of the power substrate assemblies includes a driving circuit board located at an upper layer and a power circuit board located at a lower layer; The driving circuit board comprises a low-voltage connector, an electronic device and a discharge device located on a first layer, a first insulating layer located on a second layer, and a soldering copper layer, a forward power terminal and a three-phase output power terminal located on a third layer; wherein the low-voltage connector is electrically connected to the control substrate; The power circuit board includes a second insulating layer located on the fourth layer, an upper copper layer located on the fifth layer, a third insulating layer located on the sixth and seventh layers, a negative power terminal and a lower copper layer located on the eighth layer, and an insulating thermal conductive layer located on the ninth layer; wherein the third insulating layer is embedded with a semiconductor chip; wherein the lower copper layer and the upper copper layer are connected to the semiconductor chip through copper plating vias; wherein the negative power terminal and the positive power terminal are electrically connected to the capacitor filter assembly.

8. The motor controller according to claim 7, characterized in that: There are multiple semiconductor chips.

9. The motor controller according to claim 5, characterized in that: The motor controller further comprises a hollow shell; the external shell and the hollow shell are both cylindrical; The capacitor filter assembly, the shielding plate, the control substrate, the upper cover and the bottom cover are all provided with through holes for installing the hollow housing.

10. A motor control system, characterized in that: The motor control system comprises a motor and a motor controller as claimed in claim 9; The motor comprises a motor body and an output shaft, and the output shaft is mounted on the hollow housing.

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