Controller assembly and drive system

Abstract

The present invention discloses a controller assembly, which includes a domain control board, a PDM, a capacitor, a drive motor drive board, a drive motor IGBT, an integrated water channel, a generator IGBT and a drive control integrated board from top to bottom; the capacitor and the integrated water channel are arranged side by side below the PDM, the drive motor IGBT is located above the integrated water channel, and the generator IGBT is located below the integrated water channel; the drive motor drive board is located between the drive motor IGBT and the PDM, and the drive control integrated board is located below the generator IGBT and the capacitor. The present invention realizes a high degree of integration of the controller, and the integrated water channel is located between the drive motor IGBT and the generator IGBT, which can cool the drive motor IGBT and the generator IGBT at the same time, thereby improving the cooling efficiency of the controller assembly.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile drive systems, and in particular to a controller assembly and a drive system. Background Art

[0002] As one of the core components of modern automobiles, the automobile controller assembly has a profound impact on the performance, safety and reliability of the automobile.

[0003] The controller assembly usually includes a control module, a drive module, a power module, and various interfaces. With the high degree of integration of the drive system, the controller assembly also needs to integrate more functional modules and electronic components, which places higher requirements on the internal structure layout and cooling efficiency of the controller assembly.

[0004] Therefore, it is necessary to design a controller assembly and drive system with high integration and excellent cooling performance. Summary of the invention

[0005] The purpose of the present invention is to overcome the deficiencies of the prior art and provide a controller assembly and a drive system with high integration and excellent cooling performance.

[0006] The technical solution of the present invention provides a controller assembly, which includes, from top to bottom, a domain control board, a PDM, a capacitor, a drive motor drive board, a drive motor IGBT, an integrated water channel, a generator IGBT and a drive control integrated board;

[0007] The capacitor and the integrated water channel are arranged side by side below the PDM, the drive motor IGBT is located above the integrated water channel, and the generator IGBT is located below the integrated water channel;

[0008] The drive motor drive board is located between the drive motor IGBT and the PDM, and the drive control integrated board is located below the generator IGBT and the capacitor.

[0009] Furthermore, it also includes a controller cover, which includes a small cover and a large cover, the domain control board is arranged between the small cover and the large cover, the small cover is located above the domain control board, and the large cover is located above the PDM.

[0010] Further, the PDM includes a PDM water channel, and the PDM water channel is connected in series with the integrated water channel.

[0011] Furthermore, the integrated water channel includes an upper water channel and a lower water channel, the upper water channel is used to cool the drive motor IGBT, and the lower water channel is used to cool the generator IGBT.

[0012] The present invention also provides a drive system, including a main housing, a drive motor, a generator, a reducer and a speed increaser, and also includes a controller assembly as described in any of the above items, wherein the main housing includes a drive motor housing, a generator housing, a transmission housing and a controller housing, the drive motor is installed in the drive motor housing, the generator is installed in the generator housing, the reducer and the speed increaser are installed in the transmission housing, and the controller assembly is installed in the controller housing.

[0013] Furthermore, the controller assembly also includes a controller top cover, which includes a small cover and a large cover, the domain control board is arranged between the small cover and the large cover, the small cover is located above the domain control board, the large cover is located above the PDM, and the large cover is sealed and connected to the opening of the controller housing.

[0014] Furthermore, a water cooling inlet pipe and a water cooling outlet pipe are provided in the main shell;

[0015] The PDM comprises a PDM water channel, the PDM water channel is connected in series with the integrated water channel, and the water-cooling inlet pipe and the water-cooling outlet pipe are connected to the PDM water channel.

[0016] Furthermore, the PDM water channel includes a capacitor cooling unit and a PDM cooling unit, and the capacitor cooling unit and the PDM cooling unit are connected in series.

[0017] Furthermore, the drive system also includes an oil cooler, and the water-cooling outlet pipe is connected to the oil cooler.

[0018] Furthermore, the PDM is provided with a shell water inlet, a shell water outlet, an integrated water channel inlet and an integrated water channel outlet, the water cooling inlet pipe is connected to the shell water inlet, the integrated water channel inlet is connected to the inlet of the integrated water channel, the integrated water channel outlet is connected to the outlet of the integrated water channel, and the shell water outlet is connected to the water cooling outlet pipe.

[0019] After adopting the above technical solution, the following beneficial effects are achieved:

[0020] The present invention integrates the domain control board, PDM, capacitor, drive motor drive board, drive motor IGBT, integrated water channel, generator IGBT and drive control integrated board into the controller assembly, thereby realizing a high degree of integration of the controller. The integrated water channel is located between the drive motor IGBT and the generator IGBT, and can cool the drive motor IGBT and the generator IGBT at the same time, thereby improving the cooling efficiency of the controller assembly. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The disclosure of the present invention will become more easily understood with reference to the accompanying drawings. It should be understood that these drawings are only for illustrative purposes and are not intended to limit the scope of protection of the present invention. In the drawings:

[0022] Figure 1 is a three-dimensional diagram of a controller assembly in one embodiment of the present invention;

[0023] Figure 2 yes Figure 1 Exploded diagram of

[0024] Figure 3 The drive assembly of one embodiment of the present invention is Figure 1 ;

[0025] Figure 4 is an exploded view of a drive assembly in one embodiment of the present invention;

[0026] Figure 5 The drive assembly of one embodiment of the present invention is Figure 2 ;

[0027] Figure 6 The drive assembly of one embodiment of the present invention is Figure 3 ;

[0028] Figure 7 is a top view of the main housing in one embodiment of the present invention;

[0029] Figure 8 is a cross section of a PDM in one embodiment of the present invention Figure 1 ;

[0030] Fig. 9 is a cross section of a PDM in one embodiment of the present invention Figure 2 ;

[0031] Fig.10 is a three-dimensional diagram of an integrated waterway in one embodiment of the present invention;

[0032] Fig.11 is a longitudinal cross-sectional view of an integrated water channel in one embodiment of the present invention;

[0033] Fig.12 is a schematic diagram of a PDM, an integrated water channel and a cooling circuit in a main housing in one embodiment of the present invention;

[0034] Fig.13 is an exploded view of a drive assembly in another embodiment of the present invention;

[0035] Fig.14 It is a schematic diagram of a capacitor, an integrated water channel and an inverter three-phase terminal block in another embodiment of the present invention.

[0036] Reference table of reference numerals:

[0037] Domain control board 1: cable 11;

[0038] PDM2: capacitor cooling unit 21, PDM cooling unit 22, shell water inlet 23, shell water outlet 24, integrated water channel water inlet 25, integrated water channel water outlet 26;

[0039] Capacitor 3: shielding plate 31;

[0040] Driving motor driving board 4: driving motor three-phase terminal block 41;

[0041] Drive motor IGBT5;

[0042] Integrated water channel 6: upper water channel 61, lower water channel 62, water channel water inlet 63, water channel water outlet 64, upper row inverter three-phase wiring socket 65, lower row inverter three-phase wiring socket 66;

[0043] Generator IGBT7;

[0044] Drive control integrated board 8: generator three-phase terminal block 81;

[0045] Controller upper cover 9: small cover 91, large cover 92;

[0046] Main housing 10: drive motor housing 101, generator housing 102, transmission housing 103, controller housing 104, water cooling inlet pipe 105, water cooling outlet pipe 106;

[0047] Oil cooler 20. DETAILED DESCRIPTION

[0048] The specific implementation of the present invention will be further described below in conjunction with the accompanying drawings.

[0049] It is easy to understand that according to the technical solution of the present invention, without changing the essential spirit of the present invention, a person skilled in the art can replace various structural modes and implementation modes with each other. Therefore, the following specific implementation modes and drawings are only exemplary descriptions of the technical solution of the present invention, and should not be regarded as the whole of the present invention or as a limitation or restriction to the technical solution of the invention.

[0050] The directional terms such as up, down, left, right, front, back, front, back, top, bottom, etc. mentioned or may be mentioned in this specification are defined relative to the structures shown in the drawings. They are relative concepts and may change accordingly according to different positions and different usage conditions. Therefore, these or other directional terms should not be interpreted as restrictive terms.

[0051] In some embodiments of the present invention, Figure 1-Figure 2As shown, the controller assembly includes, from top to bottom, a domain control board 1, a PDM 2, a capacitor 3, a drive motor drive board 4, a drive motor IGBT 5, an integrated water channel 6, a generator IGBT 7 and a drive control integrated board 8;

[0052] The capacitor 3 and the integrated water channel 6 are arranged side by side below the PDM2, the drive motor IGBT5 is located above the integrated water channel 6, and the generator IGBT7 is located below the integrated water channel 6;

[0053] The drive motor drive board 4 is located between the drive motor IGBT5 and the PDM2 , and the drive control integrated board 8 is located below the generator IGBT7 and the capacitor 3 .

[0054] Specifically, the domain control board 1 is located above the PDM2. The domain control board 1 integrates the vehicle controller VCU, the high-voltage battery management system HBMS, the heat pump air conditioning control HVAC, the cabin thermal management TMS, the drive motor control MCU, the charging protocol conversion EVCC, the low-voltage battery management LBMS, the drive anti-skid system dTCS and the high-voltage reverse pre-charging function. The domain control board 1 is connected to the drive motor drive board 4 through the cable 11.

[0055] As a part of the electric vehicle power bus system, PDM2 is used for power conversion, stability control and temperature management of the electric vehicle power system.

[0056] The capacitor 3 is located below the PDM2 and is also located on the side of the drive motor drive board 4, the drive motor IGBT 5, the integrated water channel 6 and the generator IGBT 7.

[0057] The drive motor driving board 4 is used alone as a drive board of the drive motor and is located above the drive motor IGBT5.

[0058] The drive motor IGBT5 is directly located above the integrated water channel 6 , and the integrated water channel 6 can cool the drive motor IGBT5 .

[0059] The generator IGBT7 is directly located below the integrated water channel 6 , and the integrated water channel 6 can cool the generator IGBT7 at the same time.

[0060] The drive control integrated board 8 is located at the bottom, and the drive control integrated board 8 integrates the control functions of the generator drive control, oil pump, electromagnetic clutch and switch electromagnetic valve.

[0061] The drive motor IGBT5 is connected to the drive motor (not shown) via the drive motor three-phase terminal block 41 , and the generator IGBT7 is connected to the generator (not shown) via the generator three-phase terminal block 81 .

[0062] In this embodiment, the domain control board 1, PDM2, capacitor 3, drive motor drive board 4, drive motor IGBT5, integrated water channel 6, generator IGBT7 and drive control integrated board 8 are integrated into the controller assembly, realizing a high degree of integration of the controller, and the integrated water channel 6 is located between the drive motor IGBT5 and the generator IGBT7, which can cool the drive motor IGBT5 and the generator IGBT7 at the same time, thereby improving the cooling efficiency of the controller assembly.

[0063] Preferably, if Figure 2 As shown, a shielding plate 31 is further provided between the capacitor 3 and the drive control integrated board 8 .

[0064] Furthermore, if Figure 2 As shown, it also includes a controller cover 9, which includes a small cover 91 and a large cover 92. The domain control board 1 is arranged between the small cover 91 and the large cover 92. The small cover 91 is located above the domain control board 1, and the large cover 92 is located above the PDM2.

[0065] The large cover 92 is located between the domain control board 1 and the PDM2. The domain control board 1 and the PDM2 share the large cover 92, which can reduce the Z-direction (height direction) size of the controller assembly.

[0066] like Figure 3-Figure 4 As shown, the area of ​​the small cover 91 is smaller than that of the large cover 92. The small cover 91 is used to cover the domain control board 1 on the large cover 92. The large cover 92 is used to connect with the main housing 10 of the drive system to realize the installation of PDM2, capacitor 3, drive motor drive board 4, drive motor IGBT5, integrated water channel 6, generator IGBT7 and drive control integrated board 8 in the main housing 10.

[0067] Furthermore, PDM2 includes a PDM water channel, which is connected in series with an integrated water channel 6. Cooling water first enters the PDM water channel to cool the capacitor 3 and the internal components of PDM2, and then flows into the integrated water channel 6, which cools the drive motor IGBT5 and the generator IGBT7, thereby improving the cooling efficiency.

[0068] Furthermore, if Figure 10-11 As shown, the integrated water channel 6 includes an upper water channel 61 and a lower water channel 62 . The upper water channel 61 is used to cool the drive motor IGBT5 , and the lower water channel 62 is used to cool the generator IGBT7 .

[0069] Specifically, Fig.10 As shown, the integrated water channel 6 also includes a water channel inlet 63 and a water channel outlet 64. The water channel inlet 63 is connected to the PDM water channel. The coolant flows into the upper water channel 61 from the water channel inlet 63. The upper water channel 61 is in direct contact with the drive motor IGBT5 to cool the drive motor IGBT.

[0070] like Fig.11 As shown, the coolant flows downward from one side of the upper water channel 61 into the lower water channel 62, and the lower water channel 62 is in direct contact with the generator IGBT 7, thereby cooling the generator IGBT 7. The coolant finally flows into the PDM 2 again from the water channel outlet 64.

[0071] In this embodiment, the controller assembly integrates more components, and the components are arranged more compactly, occupying a smaller volume. In addition, the integrated water channel can cool the drive motor IGBT5 and the generator IGBT7 at the same time, thereby improving the cooling efficiency. The integrated water channel is also connected in series with the PDM water channel, further improving the cooling efficiency.

[0072] In some other embodiments of the present invention, Figure 3-Figure 5 As shown, the drive system includes a main housing 10, a drive motor, a generator, a reducer and a speed increaser, and also includes a controller assembly of any of the above items. The main housing 10 includes a drive motor housing 101, a generator housing 102, a transmission housing 103 and a controller housing 104. The drive motor is installed in the drive motor housing 101, the generator is installed in the generator housing 102, the reducer and the speed increaser are installed in the transmission housing 103, and the controller assembly is installed in the controller housing 104.

[0073] Specifically, the drive motor housing 101 and the generator housing 102 are located on the same side, the transmission housing 103 is located on the other side, and the drive motor housing 101 is higher than the generator housing 102. The controller housing 104 is located above the generator housing 102, and the top surface of the controller housing 104 is substantially flush with the highest point of the drive motor housing 101. The controller housing 104 just utilizes the space of the height difference between the drive motor housing 101 and the generator housing 102, making the overall structure more compact and occupying less space.

[0074] Furthermore, if Figure 4 As shown, the controller assembly also includes a controller upper cover 9, which includes a small cover 91 and a large cover 92. The domain control board 1 is arranged between the small cover 91 and the large cover 92. The small cover 91 is located above the domain control board 1, and the large cover 92 is located above the PDM. The large cover 92 is sealed and connected to the opening of the controller housing 104, and the PDM2, capacitor 3, drive motor drive board 4, drive motor IGBT5, integrated water channel 6, generator IGBT7 and drive control integrated board 8 are installed in the controller housing 104.

[0075] Furthermore, if Figure 5 and Fig.12 As shown, a water cooling inlet pipe 105 and a water cooling outlet pipe 106 are provided in the main housing 10;

[0076] PDM2 includes a PDM water channel, the PDM water channel is connected in series with the integrated water channel 6, and the water cooling inlet pipe 105 and the water cooling outlet pipe 106 are connected to the PDM water channel.

[0077] Specifically, Figure 5 As shown, the water cooling water inlet pipe 105 is arranged in the controller housing 104. Figure 7 As shown, the water cooling water inlet pipe 105 leads to the interior of the controller housing 104. Since the PDM2 is installed in the controller housing 104, as shown in FIG. Figure 8 As shown, the water cooling inlet pipe 105 is directly connected to the shell water inlet 23 of the PDM water channel. The coolant flows from the water cooling inlet pipe 105 into the PDM water channel, then flows from the PDM water channel into the integrated water channel 6, then flows from the integrated water channel 6 back to the PDM water channel again, and finally flows from the PDM water channel into the water cooling outlet pipe 106, and the water cooling outlet pipe 106 penetrates from the controller shell 104 into the generator shell 102.

[0078] like Figure 6 As shown, the drive system further includes an oil cooler 20, and a water cooling outlet pipe 106 is connected to the oil cooler 20. Since the oil cooler 20 is mounted on the generator housing 102, the water cooling outlet pipe 106 is connected to the oil cooler 20, and the oil cooler 20 is continuously cooled, specifically, the oil in the oil cooler 20 is cooled, and finally the coolant flows out of the oil cooler 20 and flows into the cooling system of the vehicle to cool the coolant.

[0079] Furthermore, if Fig. 9 As shown, the PDM water channel includes a capacitor cooling unit 21 and a PDM cooling unit 22, and the capacitor cooling unit 21 and the PDM cooling unit 22 are connected in series.

[0080] like Fig.12 As shown, since the capacitor 3 is installed below the PDM 2, the capacitor cooling unit 21 contacts the upper surface of the capacitor 3 and is used to cool the capacitor 3. The coolant first flows into the capacitor cooling unit 21 and then flows into the PDM cooling unit 22. The PDM cooling unit 22 is drawer-shaped and can cool the side and bottom surfaces of the components located therein.

[0081] Furthermore, if Figure 8 and Fig.12 As shown, PDM2 is provided with a shell water inlet 23, a shell water outlet 24, an integrated water channel inlet 25 and an integrated water channel outlet 26, the water cooling inlet pipe 105 is connected to the shell water inlet 24, the integrated water channel inlet 25 is connected to the water channel inlet 63 of the integrated water channel 6, the integrated water channel outlet 26 is connected to the water channel outlet 64 of the integrated water channel 6, and the shell water outlet 24 is connected to the water cooling outlet pipe 106.

[0082] Specifically, Figure 8As shown, the shell water inlet 23 and the integrated water channel water inlet 25 are arranged at positions corresponding to the capacitor cooling unit 21 and the PDM cooling unit 22 , and the shell water outlet 24 and the integrated water channel water outlet 26 are arranged beside the PDM cooling unit 22 .

[0083] like Fig.12 As shown, the flow direction of the cooling circuit of the coolant is as follows: water cooling inlet pipe 105—shell water inlet 23—capacitor cooling unit 21—PDM cooling unit 22—integrated water channel inlet 25—water channel inlet 63—upper water channel 61—downstream water channel 62—water channel outlet 64—integrated water channel outlet 26—shell water outlet 24—water cooling outlet pipe 106.

[0084] The water-cooling outlet pipe 106 includes three sections, and the water-cooling outlet pipe 106 extends from the inside of the controller housing 104 to the inside of the generator housing 102 , so as to be connected with the oil cooler 20 installed on the generator housing 102 .

[0085] It should be noted that Fig.12 The coolant is materialized to clearly show the flow path of the coolant.

[0086] The cooling circuit of the drive system in this embodiment is connected to the cooling system of the entire vehicle. The cooling circuit is formed by the arrangement of the main shell 10, PDM2 and the integrated water channel 6. All cooling circuits are arranged inside the main shell 10 and do not require external pipes, making the overall structure of the drive system more compact and occupying less space.

[0087] In another embodiment of the present invention, Figure 13-14 As shown, the capacitor 3 and the integrated water channel 6 are integrally formed, making the overall structure more compact. The internal structures of the capacitor 3 and the integrated water channel 6 remain unchanged.

[0088] In addition, the integrated waterway 6 also integrates an upper row inverter three-phase terminal block 65 and a lower row inverter three-phase terminal block 66. The upper row inverter three-phase terminal block 65 connects the drive motor IGBT5 and the drive motor three-phase terminal block 41, and the lower row inverter three-phase terminal block 66 connects the generator IGBT7 and the generator three-phase terminal block 81.

[0089] The structure of the integrated capacitor 3, the integrated water channel 6 and the inverter three-phase terminal block is more compact and convenient for wiring connection.

[0090] The above description is only the principle and preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this field, several other modifications can be made based on the principle of the present invention, which should also be considered as the protection scope of the present invention.

Claims

1. A controller assembly, characterized in that: From top to bottom, it includes domain control board, PDM, capacitor, drive motor drive board, drive motor IGBT, integrated water channel, generator IGBT and drive control integrated board; The capacitor and the integrated water channel are arranged side by side below the PDM, the drive motor IGBT is located above the integrated water channel, and the generator IGBT is located below the integrated water channel; The drive motor drive board is located between the drive motor IGBT and the PDM, and the drive control integrated board is located below the generator IGBT and the capacitor.

2. The controller assembly according to claim 1, characterized in that: It also includes a controller cover, which includes a small cover and a large cover. The domain control board is arranged between the small cover and the large cover. The small cover is located above the domain control board, and the large cover is located above the PDM.

3. The controller assembly according to claim 1, characterized in that: The PDM includes a PDM water channel, and the PDM water channel is connected in series with the integrated water channel.

4. The controller assembly according to claim 1, characterized in that: The integrated water channel includes an upper water channel and a lower water channel, the upper water channel is used to cool the drive motor IGBT, and the lower water channel is used to cool the generator IGBT.

5. A drive system, comprising a main housing, a drive motor, a generator, a reducer and a speed increaser, characterized in that: It also includes the controller assembly described in any one of claims 1-4, the main housing includes a drive motor housing, a generator housing, a transmission housing and a controller housing, the drive motor is installed in the drive motor housing, the generator is installed in the generator housing, the reducer and the speed increaser are installed in the transmission housing, and the controller assembly is installed in the controller housing.

6. The drive system according to claim 5, characterized in that: The controller assembly also includes a controller upper cover, which includes a small cover and a large cover. The domain control board is arranged between the small cover and the large cover. The small cover is located above the domain control board, and the large cover is located above the PDM. The large cover is sealed and connected to the opening of the controller housing.

7. The drive system according to claim 5, characterized in that: The main housing is provided with a water cooling inlet pipe and a water cooling outlet pipe; The PDM comprises a PDM water channel, the PDM water channel is connected in series with the integrated water channel, and the water-cooling inlet pipe and the water-cooling outlet pipe are connected to the PDM water channel.

8. The drive system according to claim 7, characterized in that: The PDM water channel includes a capacitor cooling unit and a PDM cooling unit, and the capacitor cooling unit and the PDM cooling unit are connected in series.

9. The drive system according to claim 7, characterized in that: The driving system also includes an oil cooler, and the water-cooling outlet pipe is connected to the oil cooler.

10. The driving system according to claim 7, characterized in that: The PDM is provided with a shell water inlet, a shell water outlet, an integrated water channel inlet and an integrated water channel outlet; the water cooling inlet pipe is connected to the shell water inlet, the integrated water channel inlet is connected to the inlet of the integrated water channel, the integrated water channel outlet is connected to the outlet of the integrated water channel, and the shell water outlet is connected to the water cooling outlet pipe.

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