Motor controller structure for new energy automobile

Abstract

The invention relates to a motor controller structure for a new energy automobile, and the structure comprises a box body and a box cover, and a filtering assembly, a thin-film capacitor, a PCB, a switching copper bar and a power heat dissipation assembly which are disposed in an inner cavity formed by the box body and the box cover, and the thin-film capacitor, the power heat dissipation assembly and the switching copper bar are connected in sequence. The power heat dissipation assembly comprises a ceramic substrate, a heat dissipation device, a pressing plate and a plurality of single tube modules, the ceramic substrate is arranged on the first side of the heat dissipation device, all the single tube modules are arranged side by side, arranged on the ceramic substrate and then pressed by the pressing plate, a heat exchange cavity is formed in the second side of the power heat dissipation assembly, and heat dissipation fins are arranged in the heat exchange cavity. Compared with the prior art, the overall integration degree is improved, a good heat dissipation effect is achieved, the design of the radiator is not limited to the influence of the internal structure of the box body any more, and the controller box body heat dissipation device can be compatible with different controller box bodies.

Description

Technical Field

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

[0002] For conventional motor controllers, the power module used is a full-bridge standard package module. Since the package volume of the standard IGBT module is large, the volume of the controller is correspondingly large, which makes it difficult to achieve the effect of improving the power density of the controller to a certain extent. In addition, due to the need for module heat dissipation, it is necessary to design an independent heat dissipation channel at the corresponding position on the box so that the module can work normally during operation. The design of the heat dissipation channel needs to be arranged according to the overall structure of the box, which has certain limitations during design and is difficult to design. In addition, the connection between the IGBT module, the thin film capacitor and the three-phase in the traditional motor controller is mainly achieved by bolts to fix the two. However, when the bolts become loose, sparks will occur, which will cause the electronic components to burn out and cause the motor controller to fail.

[0003] Although some existing technologies improve the output capacity of the motor controller by connecting single tubes in parallel, since such existing technologies do not integrate the parallel single tubes with other modules such as heat dissipation, there are still problems such as the difficulty in designing the above-mentioned heat dissipation water channel and the bolts are easy to loosen. Summary of the invention

[0004] The purpose of the present invention is to provide a motor controller structure for new energy vehicles. By arranging multiple single-tube modules side by side and arranging them on a radiator based on a ceramic substrate, a heat exchange cavity containing cooling fins is arranged on the other side of the radiator, thereby improving the overall integration. Not only does it have a better heat dissipation effect, but the design of the radiator is no longer limited to the influence of the internal structure of the box, and can be compatible with different controller boxes.

[0005] The purpose of the present invention can be achieved by the following technical solutions:

[0006] A motor controller structure for new energy vehicles, comprising a box body and a box cover, and a filter component, a film capacitor, a PCB board, a transfer copper bus and a power heat dissipation component arranged in an inner cavity formed by the box body and the box cover, wherein the film capacitor, the power heat dissipation component and the transfer copper bus are connected in sequence, and the power heat dissipation component comprises a ceramic substrate, a radiator, a pressing plate and a plurality of single-tube modules, wherein the ceramic substrate is arranged on a first side of the radiator, and all the single-tube modules are arranged side by side and pressed by the pressing plate after being arranged on the ceramic substrate, and a heat exchange cavity is arranged in the second side of the power heat dissipation component, and heat dissipation fins are arranged in the heat exchange cavity.

[0007] The output end of the film capacitor and the input end of the power heat dissipation component are connected by laser welding, and the output end of the power heat dissipation component and the input end of the transfer copper bus are connected by laser welding.

[0008] The radiator shell of the radiator is connected to the box body.

[0009] The filter component, film capacitor, power heat dissipation component and transfer copper bus are laid flat in the box.

[0010] The controller structure also includes a three-phase bracket, and the PCB board is installed in the box through the three-phase bracket, and the PCB board is stacked above the film capacitor and the power heat dissipation component.

[0011] A shielding plate is provided between the film capacitor and the PCB board.

[0012] An arched ring is provided on the edge of the surface of the box cover facing the outer side of the inner cavity, and the height of the arched ring increases gradually from the inside of the outer box.

[0013] The box cover is also provided with labyrinth reinforcement ribs on the surface facing the outer side of the inner cavity, and the labyrinth reinforcement ribs are located in the center of the arch ring.

[0014] The arched ring is provided with strip reinforcing ribs.

[0015] The filter assembly includes a nanocrystalline magnetic ring, a first Y capacitor, a first ferrite magnetic ring, a second Y capacitor and a second ferrite magnetic ring which are arranged in sequence.

[0016] Compared with the prior art, the present invention has the following beneficial effects:

[0017] 1. By arranging multiple single-tube modules side by side and setting them on the radiator based on the ceramic substrate, a heat exchange cavity containing cooling fins is set on the other side of the radiator, thereby improving the overall integration, not only achieving a better heat dissipation effect, but also the design of the radiator is no longer limited to the internal structure of the box, and can be compatible with different controller boxes.

[0018] 2. A more integrated assembly solution is adopted, and the traditional bolt fixing solution is replaced by laser welding to connect copper busbars, which improves the reliability of electrical connection.

[0019] 3. The upper end surface of the box cover is arched, and is provided with labyrinth-type reinforcement ribs and strip reinforcement ribs, which can greatly improve the mode of the box cover. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a structural schematic diagram of the present invention;

[0021] Figure 2 Schematic diagram of the explosion structure of the power heat dissipation component

[0022] Figure 3 It is a schematic diagram of the structure of the radiator housing and cover plate;

[0023] Figure 4 This is a schematic diagram of the exploded structure of the core power component of the motor controller;

[0024] Figure 5 Schematic diagram of the box cover

[0025] Figure 6 is a schematic diagram of the structure of the filter component;

[0026] Wherein: 1. box body, 2. box cover, 3. filter assembly, 4. film capacitor, 5. shielding plate, 6. PCB board, 7. three-phase bracket, 8. transfer copper busbar, 9. power heat dissipation assembly, 21. arch ring, 22. labyrinth reinforcement rib, 23. strip reinforcement rib, 24. local avoidance part, 31. nanocrystalline magnetic ring, 32. first Y capacitor, 33. first ferrite magnetic ring, 34. second Y capacitor, 35. second ferrite magnetic ring, 36. filter bracket, 41. output end of film capacitor, 81. input end of transfer copper busbar, 91. single tube module, 92. ceramic substrate, 93. radiator, 94. pressure plate, 95. input end of power heat dissipation assembly, 931. radiator shell, 932. heat dissipation fin, 933. cover plate. DETAILED DESCRIPTION

[0027] The present invention is described in detail below in conjunction with the accompanying drawings and specific embodiments. This embodiment is implemented based on the technical solution of the present invention, and provides a detailed implementation method and specific operation process, but the protection scope of the present invention is not limited to the following embodiments.

[0028] A motor controller structure for new energy vehicles, such as Figure 1 As shown, it includes a box body 1 and a box cover 2, and a filter component 3, a film capacitor 4, a PCB board 6, a transfer copper bus 8 and a power heat dissipation component 9 arranged in the inner cavity formed by the box body 1 and the box cover 2. The film capacitor 4, the power heat dissipation component 9, and the transfer copper bus 8 are connected in sequence. Figure 2 As shown, the power heat dissipation component 9 includes a ceramic substrate 92, a heat sink 93, a pressing plate 94 and a plurality of single-tube modules 91. The ceramic substrate 92 is arranged on a first side of the heat sink 93. All the single-tube modules 91 are arranged side by side and arranged on the ceramic substrate 92 and then pressed by the pressing plate 94. Figure 3 As shown, a heat exchange cavity is provided in the second side of the power heat dissipation component 9, and heat dissipation fins 932 are provided in the heat exchange cavity. In addition, a cover plate 933 is provided on the heat exchange cavity for sealing.

[0029] By arranging multiple single-tube modules 91 side by side and arranging them on a radiator 93 based on a ceramic substrate 92, and arranging a heat exchange cavity containing cooling fins 932 on the other side of the radiator 93, the overall integration is improved, which not only has a better heat dissipation effect, but also the design of the radiator 93 is no longer limited to the internal structure of the box, and can be compatible with different controller boxes.

[0030] In certain embodiments, such as Figure 4 As shown, the output end of the film capacitor 4 and the input end of the power heat sink assembly 9 are connected by laser welding, and the output end of the power heat sink assembly 9 and the input end of the transfer copper bus 8 are connected by laser welding. A more integrated assembly solution is adopted, and the copper bus is connected by laser welding instead of the traditional bolt fixing solution, which improves the reliability of the electrical connection.

[0031] In this embodiment, the radiator housing 931 of the radiator 93 is directly connected to the box body 1 to save space.

[0032] like Figure 1 and Figure 4 As shown, the filter component 3, the film capacitor 4, the power heat dissipation component 9 and the transfer copper bus 8 are laid flat in the box 1, thereby improving the space utilization and eliminating unnecessary electrical connection structures.

[0033] In addition, the controller structure also includes a three-phase bracket 7, and the PCB board 6 is installed in the box 1 through the three-phase bracket 7, and the PCB board 6 is stacked above the film capacitor 4 and the power heat dissipation component 9 to improve space utilization, and a shielding plate 5 is provided between the film capacitor 4 and the PCB board 6 to improve stability and anti-electromagnetic interference capability.

[0034] like Figure 5 As shown, the edge of the surface of the box cover 2 facing the outer side of the inner cavity is provided with an arched ring, and the height of the arched ring increases from the inner side of the outer box. The surface of the box cover 2 facing the outer side of the inner cavity is also provided with a labyrinth reinforcement rib 22, and the labyrinth reinforcement rib 22 is located in the center of the arched ring. In addition, a strip reinforcement rib 23 is provided on the arched ring. The upper end surface of the box cover 2 is arched, and the labyrinth reinforcement rib 22 and the strip reinforcement rib 23 are provided, which can greatly improve the modality of the box cover.

[0035] like Figure 6 As shown, the filter component 3 includes a nanocrystalline magnetic ring 31, a first Y capacitor 32, a first ferrite magnetic ring 33, a second Y capacitor 34 and a second ferrite magnetic ring 35 which are arranged in sequence.

[0036] When assembling the structure of the present application, first, the nanocrystalline magnetic ring 31, the first Y capacitor 32, the first ferrite magnetic ring 33, the second Y capacitor 34 and the second ferrite magnetic ring 35 are placed at corresponding positions of the filter bracket 36 as a filter component 1, and then the assembled filter component 1 is locked inside the controller case by bolts, and then the film capacitor 4 is fixed at the corresponding position of the controller case. At the same time, the single-tube module 91, the ceramic substrate 92, and the radiator 93 are welded together as a heat dissipation component by reflow soldering, and the pressure plate 94 is placed above the single-tube module 91 to further fix the module; then two sealing rings are placed at the corresponding notches of the box, and then the assembled power heat dissipation component 9 and the transfer copper bus 8 are fixed to the corresponding installation positions of the box by bolts. At this time, the input end of the single-tube module 91 and the output end of the film capacitor 4, and the transfer copper bus 8 of the output end of the single-tube module 91 are all fixed inside the box in the form of overlap, and then the overlap positions are welded respectively by laser welding, and then the shielding plate 5 is fixed at the position corresponding to the bolt hole, and the PCB board 6 is fixed to the position above the box and the shielding plate 5 by bolts, and the pin position of the terminal is tin-welded, and the three-phase bracket 7 is fixed above the current sensor by bolts, and finally the high-voltage plug-in, the low-voltage plug-in and the breathing valve are installed on the side wall of the controller box, and the plug-in is inserted into the socket arrangement position corresponding to the PCB, and then the box cover 2 and the position above the box 1 are locked by bolts.

Claims

1. A motor controller structure for a new energy vehicle, comprising a box body (1) and a box cover (2), and a filter component (3), a film capacitor (4), a PCB board (6), a transfer copper bus (8) and a power heat dissipation component (9) arranged in an inner cavity formed by the box body (1) and the box cover (2), wherein the film capacitor (4), the power heat dissipation component (9) and the transfer copper bus (8) are connected in sequence, and characterized in that: The power heat dissipation component (9) comprises a ceramic substrate (92), a heat sink (93), a pressure plate (94) and a plurality of single-tube modules (91); the ceramic substrate (92) is arranged on a first side of the heat sink (93); all the single-tube modules (91) are arranged side by side and arranged on the ceramic substrate (92) and then pressed by the pressure plate (94); a heat exchange cavity is arranged in the second side of the power heat dissipation component (9); and a heat exchange fin (932) is arranged in the heat exchange cavity.

2. A motor controller structure for new energy vehicles according to claim 1, characterized in that: The output end of the film capacitor (4) and the input end of the power heat dissipation component (9) are connected by laser welding, and the output end of the power heat dissipation component (9) and the input end of the transfer copper busbar (8) are connected by laser welding.

3. A motor controller structure for new energy vehicles according to claim 1, characterized in that: The radiator shell (931) of the radiator (93) is connected to the box body (1).

4. A motor controller structure for new energy vehicles according to claim 1, characterized in that: The filter component (3), the film capacitor (4), the power heat dissipation component (9) and the transfer copper bus (8) are laid flat in the box (1).

5. The motor controller structure for new energy vehicles according to claim 1, characterized in that: The controller structure also includes a three-phase bracket (7), the PCB board (6) is installed in the box (1) through the three-phase bracket (7), and the PCB board (6) is stacked above the film capacitor (4) and the power heat dissipation component (9).

6. A motor controller structure for new energy vehicles according to claim 5, characterized in that: A shielding plate (5) is provided between the film capacitor (4) and the PCB board (6).

7. A motor controller structure for new energy vehicles according to claim 1, characterized in that: An arched ring is provided on the edge of the surface of the box cover (2) facing the outer side of the inner cavity, and the height of the arched ring increases gradually from the inside of the outer box.

8. A motor controller structure for new energy vehicles according to claim 7, characterized in that: The box cover (2) is also provided with a labyrinth-type reinforcing rib (22) on the surface facing the outer side of the inner cavity, and the labyrinth-type reinforcing rib (22) is located in the center of the arch ring.

9. A motor controller structure for new energy vehicles according to claim 7 or 8, characterized in that: The arched ring is provided with strip-shaped reinforcing ribs (23).

10. A motor controller structure for new energy vehicles according to claim 1, characterized in that: The filter assembly (3) comprises a nanocrystalline magnetic ring (31), a first Y capacitor (32), a first ferrite magnetic ring (33), a second Y capacitor (34) and a second ferrite magnetic ring (35) which are arranged in sequence.

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