Low-voltage motor controller of new energy automobile

Abstract

The invention discloses a low-voltage motor controller of a new energy automobile, and relates to the technical field of automobile parts. Comprising a controller body, and the controller body comprises an aluminum substrate and a first waterproof shell arranged on the top of the aluminum substrate. The same main power board and the same control board can be compatible with two different battery schemes, the difference between the two schemes is that auxiliary source input voltage is different, the auxiliary source input voltage is the same as bus voltage for a vehicle model only equipped with a group of power batteries, the auxiliary source input voltage can be 72V or other input voltage at the moment, and the auxiliary source input voltage and the bus voltage are different. For a vehicle type provided with a storage battery and a power battery at the same time, the input voltage of the auxiliary source is 12V or 24V, and at the moment, only the driving plate needs to be replaced to meet the requirement. According to the design, the material cost is effectively reduced, switching between the waterproof grade IP65 and the waterproof grade IP67 is achieved by replacing the input waterproof shell I and the waterproof shell II, the mold opening cost of structural parts is reduced, and the use requirements of users are met.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile parts, and in particular to a low-voltage motor controller for a new energy vehicle. Background Art

[0002] With the advancement of new energy for engineering vehicles, low-voltage controllers are widely used in a variety of electric engineering vehicles, such as electric forklifts, tractors, aerial work vehicles, storage vehicles, sightseeing vehicles, sanitation vehicles and patrol vehicles. The power source of these vehicles may be only one set of power batteries, or they may be equipped with both storage batteries and power batteries.

[0003] The design of the controller needs to take into account the specific needs of different models, including the configuration of the power battery and the waterproof level requirements. Due to the variety of models, the controller needs to be designed into different models to adapt to different situations. This will increase the complexity of the design and the cost of mold opening, resulting in the inability to simply be compatible with multiple models, which has brought serious troubles to the manufacturing industry. Summary of the invention

[0004] To achieve the above object, the present invention provides the following technical solution: a low-voltage motor controller for new energy vehicles, comprising a controller body, the controller body comprising an aluminum substrate and a waterproof shell 1 arranged on the top of the aluminum substrate, the top of the aluminum substrate is sequentially provided with a main power board, a drive board and a control board located inside the waterproof shell 1; The driving board is integrated with a driving circuit, an auxiliary source circuit and a plurality of bus capacitors; The control board integrates a low-voltage power supply circuit, a single-chip circuit, a communication circuit and a voltage and current signal acquisition circuit. The bottom of the drive board is provided with an input copper busbar and a three-phase output aluminum column whose top extends through the top of the waterproof housing.

[0005] As a preferred technical solution of the present invention, the driving board is provided with assembly holes for passing the input copper busbar and the three-phase output aluminum column.

[0006] As a preferred technical solution of the present invention, the number of the input copper bars is not less than two, and the number of the three-phase output aluminum columns is not less than three.

[0007] As a preferred technical solution of the present invention, a bus port is provided at one end of the control board, and the bus port extends from an end away from the control board to one side of the waterproof housing.

[0008] As a preferred technical solution of the present invention, studs are provided at the four corners of the top of the main power board, and screws are inserted into the four corners of the driving board and screwed into the studs to achieve the connection between the main power board and the driving board.

[0009] As a preferred technical solution of the present invention, the control panel is provided with no less than one fixing bolt, and the control panel is locked inside the waterproof housing through the fixing bolt.

[0010] As a preferred technical solution of the present invention, the main power board is a single-sided double-layer aluminum-based PCB, the bottom of the main power board is coated with a layer of thermal paste and the main power board is bonded to the aluminum substrate through the thermal paste.

[0011] As a preferred technical solution of the present invention, a plurality of heat dissipation grooves are arranged on the top and both sides of the waterproof housing 1, and a sealing ring is also arranged between the waterproof housing 1 and the aluminum substrate.

[0012] As a preferred technical solution of the present invention, the four corners of the waterproof housing are all provided with escape notches for accommodating screws.

[0013] As a preferred technical solution of the present invention, a wiring mark is provided on the top of the waterproof housing 1, located on one side of the input copper busbar and the three-phase output aluminum column, and a ventilation valve is provided on one side of the waterproof housing 1.

[0014] Compared with the prior art, the present invention provides a low-voltage motor controller for new energy vehicles, which has the following beneficial effects: The low-voltage motor controller for new energy vehicles enables the same main power board and control board to be compatible with two different battery solutions. The difference between the two solutions is that the auxiliary source input voltage is different. For models equipped with only one set of power batteries, the auxiliary source input voltage is the same as the bus voltage. At this time, the auxiliary source input voltage can be 72V or other input voltages. For models equipped with both storage batteries and power batteries, the auxiliary source input voltage is 12V or 24V. At this time, only the drive board needs to be replaced to meet the needs. This design effectively reduces material costs, and by replacing the input waterproof shell 1 and waterproof shell 2, the waterproof level can be switched between IP65 and IP67, reducing the mold opening cost of structural parts and meeting user needs. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] One or more embodiments are exemplarily described by corresponding drawings, which do not limit the embodiments. Elements with the same reference numerals in the drawings are shown as similar elements, and the drawings do not constitute a scale limitation, and wherein: Figure 1 This is a schematic diagram of the structure of a low-voltage motor controller for new energy vehicles proposed by the present invention; Figure 2 This is a schematic diagram of the aluminum substrate structure of a low-voltage motor controller for new energy vehicles proposed by the present invention; Figure 3This is a schematic diagram of the structure of a main power board of a low-voltage motor controller for a new energy vehicle proposed by the present invention; Figure 4 This is a schematic diagram of the structure of a drive board of a low-voltage motor controller for a new energy vehicle proposed by the present invention; Figure 5 This is a schematic diagram of the control board structure of a low-voltage motor controller for new energy vehicles proposed by the present invention; Figure 6 This is an electrical schematic diagram of a main power board of a low-voltage motor controller for a new energy vehicle proposed by the present invention; Figure 7 This is a structural schematic diagram of a second embodiment of a low-voltage motor controller for a new energy vehicle proposed by the present invention.

[0016] In the figure: 1. Controller body; 11. Aluminum base plate; 12. Waterproof shell 1; 121. Heat sink; 122. Breathable valve; 123. Avoidance gap; 124. Wiring mark; 13. Main power board; 131. Stud; 14. Drive board; 141. Input copper bus; 142. Three-phase output aluminum column; 143. Bus capacitor; 144. Auxiliary source circuit; 145. Drive circuit; 146. Assembly hole; 15. Control board; 151. Bus port; 152. Single chip microcomputer circuit; 153. Communication circuit; 154. Low voltage power supply circuit; 155. Voltage and current signal acquisition circuit; 156. Fixing bolt; 16. Waterproof shell 2; 161. Waterproof cover; 162. Connecting seat; 163. Waterproof connector. DETAILED DESCRIPTION

[0017] In order to be able to understand the features and technical contents of the embodiments of the present disclosure in more detail, the implementation of the embodiments of the present disclosure is described in detail below in conjunction with the accompanying drawings. The attached drawings are for reference only and are not used to limit the embodiments of the present disclosure. In the following technical description, for the convenience of explanation, a full understanding of the disclosed embodiments is provided through multiple details. However, one or more embodiments can still be implemented without these details. In other cases, to simplify the drawings, well-known structures and devices can be simplified for display.

[0018] The terms "first", "second", etc. in the specification and claims of the embodiments of the present disclosure and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the terms used in this way can be interchanged where appropriate, so that the embodiments of the embodiments of the present disclosure described herein. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions.

[0019] In the embodiments of the present disclosure, the terms "upper", "lower", "inside", "middle", "outside", "front", "back" and the like indicate directions or positional relationships based on the directions or positional relationships shown in the accompanying drawings. These terms are mainly intended to better describe the embodiments of the present disclosure and their embodiments, and are not intended to limit the indicated devices, elements or components to have a specific direction, or to be constructed and operated in a specific direction. Moreover, in addition to being used to indicate directions or positional relationships, some of the above terms may also be used to indicate other meanings. For example, the term "upper" may also be used to indicate a certain dependency or connection relationship in certain circumstances. For those of ordinary skill in the art, the specific meanings of these terms in the embodiments of the present disclosure can be understood according to specific circumstances.

[0020] In addition, the terms "disposed", "connected", and "fixed" should be understood in a broad sense. For example, "connected" can be a fixed connection, a detachable connection, or an integral structure; it can be a mechanical connection, or an electrical connection; it can be a direct connection, or an indirect connection through an intermediate medium, or it can be an internal connection between two devices, elements, or components. For those of ordinary skill in the art, the specific meanings of the above terms in the embodiments of the present disclosure can be understood according to specific circumstances.

[0021] Unless otherwise stated, the term "plurality" means two or more.

[0022] It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of the present disclosure may be combined with each other.

[0023] See also Figure 1-6A low-voltage motor controller for a new energy vehicle comprises a controller body 1, wherein the controller body 1 comprises an aluminum substrate 11 and a waterproof housing 12 arranged on the top of the aluminum substrate 11, wherein the top of the aluminum substrate 11 is sequentially provided with a main power board 13, a driving board 14 and a control board 15 located inside the waterproof housing 12, wherein the driving board 14 is integrated with a driving circuit 145, an auxiliary source circuit 144 and a plurality of bus capacitors 143, wherein the control board 15 is integrated with a low-voltage power supply circuit 154, a single-chip circuit 152, a communication circuit 153 and a voltage and current signal acquisition circuit 155, wherein the driving board 14 The bottom is provided with an input copper bar 141 and a three-phase output aluminum column 142, the top of which penetrates to the top of the waterproof shell 12. The low-voltage motor controller for new energy vehicles enables the same main power board 13 and control board 15 to be compatible with two different battery solutions. The difference between the two solutions is that the auxiliary source input voltage is different. For models equipped with only one set of power batteries, the auxiliary source input voltage is the same as the bus voltage. At this time, the auxiliary source input voltage can be 72V or other input voltages. For models equipped with both storage batteries and power batteries, the auxiliary source input voltage is 12V or 24V. At this time, only the drive board 14 needs to be replaced to meet the needs. This design effectively reduces the material cost, and by replacing the input waterproof shell 12 and the waterproof shell 2 16, the waterproof level can be switched between IP65 and IP67, reducing the mold opening cost of the structural parts and meeting the user's use needs.

[0024] As a specific technical solution of this embodiment, the driving plate 14 is provided with an assembly hole 146 inside for passing the input copper bus 141 and the three-phase output aluminum column 142 .

[0025] In this embodiment, the bus capacitor 143 mainly functions to smooth the bus voltage, so that the bus voltage of the motor controller is still relatively smooth when the MOS switch is on, reduce the inductance parameters of the line from the MOS end of the motor controller to the power battery end, weaken the peak voltage of the bus, absorb the high pulse current of the bus end of the motor controller, and prevent the overcharge of the bus end voltage and the influence of the transient voltage on the motor controller; the driving circuit 145 mainly functions to provide sufficient driving capability. Since the driving signal is often given by the controller's single-chip microcomputer, the driving voltage and current are not enough to turn on the switch tube, so the driving circuit is required. 145 performs driving capability matching to ensure a good switching state of the switch tube, ensure the reliability of the device, and avoid overvoltage and overcurrent; the main function of the auxiliary source circuit 144 is to convert the auxiliary source input voltage into multiple voltages for use by the control board 15 and the drive circuit 145 respectively. The innovation of this patent solution is that the auxiliary source transformer can be replaced on the same single board to achieve compatibility between low-voltage 12V and high-voltage 72V auxiliary source inputs to adapt to different external auxiliary source input conditions and adapt to vehicle models with different battery configuration solutions. The assembly hole 146 is used to install the input copper bus 141 and the three-phase output aluminum column 142.

[0026] As a specific technical solution of this embodiment, the number of the input copper busbars 141 is not less than two, the number of the three-phase output aluminum columns 142 is not less than three, a bus port 151 is provided at one end of the control board 15, and the end of the bus port 151 away from the control board 15 penetrates to one side of the waterproof shell 12, and studs 131 are provided at the top four corners of the main power board 13, and screws are inserted into the four corners of the drive board 14 and screwed into the inside of the studs 131 to achieve the connection between the main power board 13 and the drive board 14, and at least one fixing bolt 156 is provided on the control board 15, and the control board 15 is locked inside the waterproof shell 12 by the fixing bolt 156.

[0027] In this embodiment, the main power board 13 realizes the conversion function of high voltage and large current signals, and the control board 15 performs the conversion function of low voltage and small signals. To realize the function of the main power circuit, it is inseparable from the power supply of the low voltage power supply and the sampling feedback results of the key voltage and current signals; The control board 15 is the core of the whole scheme. The low-voltage power supply circuit 154 on the control board 15 converts the low-voltage power generated by the driving board 14 into multiple voltages of different amplitudes, which are supplied to the circuits and chips on the control board 15. The single-chip microcomputer on the control board 15 monitors the key signals of the main power board 13 through the signal transmission of the external auxiliary circuit, the sampling function of the voltage and current sampling circuit and other signal sampling circuits, so as to make corresponding control methods so that the main power conversion can be carried out stably. The communication circuit 153 on the control board 15 is used to receive and transmit the interactive information between the external device and the single-chip microcomputer, receive the control instructions of the external device to the low-voltage controller, and upload the module voltage, current, temperature and other information collected by the single-chip microcomputer to realize the intercommunication between the module and the external control device.

[0028] As a specific technical solution of this embodiment, the main power board 13 is a single-sided double-layer aluminum-based PCB, the bottom of the main power board 13 is coated with a layer of thermal paste and the main power board 13 is bonded to the aluminum substrate 11 through the thermal paste.

[0029] In this implementation plan, refer to Figure 7 The main power board 13 receives the DC bus voltage V_BATT+ and the ground line CND after filtering by the bus capacitors 143C1 and C2 as inputs, and converts the DC power into AC power through the control of six MOS tubes Q1, Q2, Q3, Q4, Q5, and Q6 to supply the three phases of the motor connected to the INV_A, INV_B, and INV_C ports. The PWM signals of the control MOS tubes are connected to DRV_UH_G, DRV_VH_G, DRV_WH_G, DRV_UL_G, DRV_VL_G, and DRV_WL_G, respectively.

[0030] As a specific technical solution of this embodiment, a plurality of heat dissipation grooves 121 are arranged on the top and both sides of the waterproof housing 12 , and a sealing ring is also arranged between the waterproof housing 12 and the aluminum substrate 11 .

[0031] In this embodiment, the setting of the sealing ring ensures the sealing between the waterproof shell 12 and the aluminum substrate 11. A through hole is provided inside the aluminum substrate 11. Screws are inserted from the bottom of the aluminum substrate 11 into the interior of the waterproof shell 12 to fix the waterproof shell 12.

[0032] As a specific technical solution of this embodiment, the four corners of the waterproof housing 12 are provided with avoidance notches 123 for avoiding screws.

[0033] In this embodiment, screws are inserted into the four corners of the aluminum substrate 11, and the aluminum substrate 11 can be fixed to the car by the screws. The avoidance notch 123 can avoid the screws used for installing the aluminum substrate 11. The aluminum substrate 11 can act as a shielding plate to prevent some components in electronic products from being radiated and interfered by electromagnetic waves, play a role in shielding electromagnetic waves, and ensure the performance of electronic circuits. The aluminum substrate 11 has high mechanical strength and toughness, can withstand certain external force impacts, and the aluminum substrate 11 has a fast heat dissipation speed. The aluminum substrate 11 can reduce the temperature of electrical products during operation, thereby improving the working efficiency of electrical appliances and extending the life of electrical products.

[0034] As a specific technical solution of this embodiment, a wiring mark 124 is provided on the top of the waterproof shell 12 on one side of the input copper bus 141 and the three-phase output aluminum column 142, and a ventilation valve 122 is provided on one side of the waterproof shell 12.

[0035] In this embodiment, the wiring mark 124 facilitates the user to connect externally, and there will be no wiring errors. The assembly process is simpler and faster. The air valve 122 can balance the air pressure inside and outside the controller to prevent deformation or sealing failure of the waterproof housing 12 due to excessive internal and external pressure difference. This helps to maintain the sealing performance of the waterproof housing 12 and prevent structural damage caused by air pressure imbalance. The air valve 122 can prevent liquids such as water and oil from entering the waterproof housing 12 to protect the device from moisture. The air valve 122 usually adopts ePTFE waterproof and breathable membrane, which can effectively isolate liquids and ensure the normal operation of the device in a humid environment. The air valve 122 can block dust and other fine particles from entering the waterproof housing 12 to prevent dust accumulation from causing equipment failure or performance degradation, which is crucial to keeping the equipment clean and running stably for a long time. The waterproof housing 12 cooperates with the aluminum substrate 11 to achieve IP65 waterproof level.

[0036] Example 2, see Figure 1-7 Compared with the above embodiment, the present embodiment further includes a second waterproof shell 16, which is used to replace the first waterproof shell 12 in the above embodiment. At least five waterproof connectors 163 are provided on one side of the second waterproof shell 16, which are used to connect input and output wires respectively. A connecting seat 162 is also provided around the bottom of the second waterproof shell 16, which is used to screw into the inside of the connecting seat 162 from the bottom of the aluminum substrate 11 to fix the second waterproof shell 16. A waterproof cover plate 161 is provided on the top of the second waterproof shell 16. Sealing rings are provided between the waterproof cover plate 161 and the second waterproof shell 16 and between the second waterproof shell 16 and the aluminum substrate 11. Heat dissipation grooves 121 are provided on the top of the waterproof cover 161 and on both sides of the waterproof housing 16. The provision of the waterproof cover 161 facilitates the inspection of the interior of the waterproof housing 16 without disassembling the waterproof housing 16. The top of the waterproof cover 161 is also provided with wiring identification marks 124 corresponding to the waterproof connectors 163. The waterproof housing 16 cooperates with the aluminum substrate 11 to achieve IP67 waterproofing. Only the drive board 14 needs to be replaced. The drive board 14 is connected through the waterproof connector 163, and the wiring method of the input copper bus 141 and the three-phase output aluminum column 142 is cancelled, and the overall sealing and waterproofing performance is further improved. ‌‌‌ In summary, the low-voltage motor controller for new energy vehicles enables the same main power board 13 and control board 15 to be compatible with two different battery solutions. The difference between the two solutions lies in the different auxiliary source input voltages. For models equipped with only one set of power batteries, the auxiliary source input voltage is the same as the bus voltage. At this time, the auxiliary source input voltage can be 72V or other input voltages. For models equipped with both storage batteries and power batteries, the auxiliary source input voltage is 12V or 24V. At this time, only the drive board 14 needs to be replaced to meet the needs. This design effectively reduces material costs, and by replacing the input waterproof shell 12 and the waterproof shell 2 16, the waterproof level can be switched between IP65 and IP67, reducing the mold opening cost of structural parts and meeting user needs.

[0037] 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. A low-voltage motor controller for a new energy vehicle, comprising a controller body (1), characterized in that: The controller body (1) comprises an aluminum substrate (11) and a waterproof housing (12) arranged on the top of the aluminum substrate (11); a main power board (13), a drive board (14) and a control board (15) are arranged in sequence on the top of the aluminum substrate (11) and are located inside the waterproof housing (12); The driving board (14) is integrated with a driving circuit (145), an auxiliary source circuit (144) and a plurality of bus capacitors (143); The control board (15) is integrated with a low-voltage power supply circuit (154), a single-chip computer circuit (152), a communication circuit (153) and a voltage and current signal acquisition circuit (155); the bottom of the drive board (14) is provided with an input copper busbar (141) whose top extends through the top of the waterproof housing (12) and a three-phase output aluminum column (142).

2. A low-voltage motor controller for new energy vehicles according to claim 1, characterized in that: The driving plate (14) is provided with an assembly hole (146) inside for passing an input copper busbar (141) and a three-phase output aluminum column (142).

3. A low-voltage motor controller for new energy vehicles according to claim 1, characterized in that: The number of the input copper bars (141) is not less than two, and the number of the three-phase output aluminum columns (142) is not less than three.

4. A low-voltage motor controller for new energy vehicles according to claim 1, characterized in that: A bus port (151) is provided at one end of the control board (15), and an end of the bus port (151) away from the control board (15) penetrates to one side of the waterproof housing (12).

5. A low-voltage motor controller for new energy vehicles according to claim 1, characterized in that: Studs (131) are provided at the four corners of the top of the main power board (13), and screws are inserted into the four corners of the drive board (14) and screwed into the inside of the studs (131), thereby achieving the connection between the main power board (13) and the drive board (14).

6. A low-voltage motor controller for new energy vehicles according to claim 1, characterized in that: The control panel (15) is provided with at least one fixing bolt (156), and the control panel (15) is locked inside the waterproof housing (12) via the fixing bolt (156).

7. A low-voltage motor controller for new energy vehicles according to claim 1, characterized in that: The main power board (13) is a single-sided double-layer aluminum-based PCB; a layer of heat dissipation paste is coated on the bottom of the main power board (13), and the main power board (13) is bonded to the aluminum substrate (11) via the heat dissipation paste.

8. A low-voltage motor controller for new energy vehicles according to claim 1, characterized in that: A plurality of heat dissipation grooves (121) are arranged on the top and both sides of the waterproof housing 1 (12), and a sealing ring is also arranged between the waterproof housing 1 (12) and the aluminum substrate (11).

9. A low-voltage motor controller for new energy vehicles according to claim 1, characterized in that: The four corners of the waterproof housing (12) are each provided with an escape notch (123) for accommodating screws.

10. A low-voltage motor controller for new energy vehicles according to claim 1, characterized in that: A wiring mark (124) is provided on the top of the waterproof housing (12) on one side of the input copper busbar (141) and the three-phase output aluminum column (142), and a vent valve (122) is provided on one side of the waterproof housing (12).

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