New energy vehicle dual motor controller core module

Abstract

This invention discloses a core module for a dual-motor controller in new energy vehicles, comprising a housing and integrated on the housing a DC support capacitor, a filter assembly, a power module, and a fuse assembly. The power module includes a power module, a current sensor, and a driver board. The current sensor is integrated inside the power module, and the power module is connected to the DC support capacitor. This core module for a dual-motor controller in new energy vehicles integrates a driver board, power module, DC support capacitor, filter assembly, current sensor, and PDU, simplifying assembly, reducing the package size of the power module, thereby increasing the controller's power density and reducing costs.

Description

Technical Field

[0001] The present invention belongs to the technical field of dual-motor controllers, and in particular, relates to a core module of a dual-motor controller for a new energy vehicle. Background Art

[0002] In recent years, the market share of pure electric and hybrid vehicles has increased year by year, and the new energy vehicle market is booming. High intelligence, good comfort, and strong controllability are attracting more and more attention. In order to meet the needs of specific groups of people, new energy vehicles are equipped with dual motors or even multiple motors, bringing a more excellent driving experience.

[0003] In the existing dual-motor controller using power modules, two power modules with different current capabilities are generally selected, one for the main drive motor and the other for the auxiliary motor. Because the two modules are packaged separately, the volume of the entire power module is often large, resulting in a larger controller size and lower power density; the material cost is high and the product competitiveness is insufficient.

[0004] It is hoped to provide an improved core module of a dual-motor controller for new energy vehicles, particularly with regard to minimizing the packaging volume of the power module, increasing the power density of the controller, and reducing costs. Summary of the invention

[0005] The present invention aims to solve at least one of the technical problems existing in the prior art. To this end, the present invention provides a core module of a dual-motor controller for a new energy vehicle, the purpose of which is to reduce the packaging volume of a power module.

[0006] In order to achieve the above-mentioned purpose, the technical solution adopted by the present invention is: a core module of a dual-motor controller for a new energy vehicle, including a shell and a DC support capacitor, a filter component, a power module and a fuse component integrated on the shell, the power module including a power module, a current sensor and a drive board, the current sensor is integrated inside the power module, and the power module is connected to the DC support capacitor.

[0007] The DC support capacitor, the filter assembly and the housing are integrated into one by glue potting.

[0008] The power module comprises a copper plate radiator, on which a pinFin for radiating heat is arranged.

[0009] The DC support capacitor and the power module are connected by laser welding.

[0010] The power module includes a first AC output interface and a second AC output interface. Each copper busbar of the first AC output interface and the second AC output interface passes through a silicon steel sheet respectively. The chip of the current sensor extends into the silicon steel sheet. The chip of the current sensor is arranged opposite to the copper busbar.

[0011] The silicon steel sheet is injection-molded in the bracket of the power module.

[0012] The power module is located at the upper end of the shell, the DC support capacitor and the filter component are integrated at the lower end of the shell, a cooling water channel is formed between the power module and the shell, and a water channel sealing ring is arranged between the power module and the shell.

[0013] A cooling medium inlet is arranged at one end of the shell, and a cooling medium outlet is arranged at the other end of the shell.

[0014] The fuse assembly integrates a fuse and a magnetic ring, the magnetic ring is installed at the front end of the bracket, the positive electrode connecting copper bar is injection molded in the bracket, one end of the fuse is fixed on the positive electrode connecting copper bar, and the other end is fixed on the bracket.

[0015] The fuse assembly is integrated with a power distribution unit.

[0016] The core module of the dual-motor controller for new energy vehicles of the present invention integrates a drive board, a power module, a DC support capacitor, a filter component, a current sensor, a PDU, etc. It is easy to assemble and can reduce the packaging volume of the power module, thereby improving the power density of the controller and reducing costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] This specification includes the following drawings, which show the following contents:

[0018] Figure 1 A top view of a dual motor controller core module provided by an embodiment of the present invention;

[0019] Figure 2 A front view of a dual motor controller core module provided by an embodiment of the present invention;

[0020] Figure 3 A bottom view of a dual-motor controller core module provided by an embodiment of the present invention;

[0021] Figure 4 An isometric view of a core module of a dual motor controller provided by an embodiment of the present invention;

[0022] Figure 5 An exploded diagram of a core module of a dual-motor controller provided by an embodiment of the present invention;

[0023] Figure 6 A bottom view of a power module provided by an embodiment of the present invention;

[0024] Figure 7 for Figure 6 A cross-sectional view of the silicon steel sheet shown;

[0025] Figure 8It is a schematic diagram of the structure of silicon steel sheet;

[0026] Fig. 9 Schematic diagram of the structure of the current sensor chip at the bottom of the driver board extending into the silicon steel sheet;

[0027] Fig.10 is an isometric view of the power module;

[0028] Fig.11 A top view of the DC support capacitor and filter components integrated on the aluminum shell;

[0029] Fig.12 A bottom view of the DC support capacitor and filter components integrated on the aluminum shell;

[0030] Fig.13 An isometric view of the DC link capacitor and filter components integrated into the aluminum housing;

[0031] Fig.14 An exploded view of the DC support capacitor and filter components integrated in the aluminum shell;

[0032] Fig.15 It is a detailed structural diagram of the DC support capacitor and filter components integrated on the aluminum shell;

[0033] Fig.16 Schematic diagram of laser welding of the copper busbar at the DC input end of the power module and the copper busbar at the output end of the DC support capacitor;

[0034] Fig.17 This is a partial enlarged view of the laser welding of the copper bars C1 and C2 at the DC input end of the power module and the copper bars C1a / C2a at the output end of the DC support capacitor;

[0035] Fig.18 is a front view of the fuse assembly;

[0036] Fig.19 is a top view of a fuse assembly;

[0037] Fig. 20 This is an exploded view of the fuse assembly;

[0038] The following are marked in the figure: 1. drive board; 2. power module; 3. water channel sealing ring; 4. housing; 5. fuse assembly. DETAILED DESCRIPTION

[0039] The specific implementation methods of the present invention are further explained in detail below by describing the embodiments with reference to the accompanying drawings, with the aim of helping those skilled in the art to have a more complete, accurate and in-depth understanding of the concept and technical solution of the present invention and facilitating its implementation.

[0040] It should be noted that, in the following embodiments, the “first” and “second” mentioned do not represent an absolute distinction in structure and / or function, nor do they represent a sequential order of execution, but are merely for the convenience of description.

[0041] like Figures 1 to 20 As shown, the present invention provides a core module of a dual-motor controller for a new energy vehicle, including a shell and a DC support capacitor, a filter component, a power module and a fuse component integrated on the shell, the power module includes a power module, a current sensor and a drive board, the current sensor is integrated inside the power module, and the power module is connected to the DC support capacitor.

[0042] Specifically, two motors are provided on a new energy vehicle, and the power module is used to connect with the two motors of the new energy vehicle to realize the control of the two motors, one of which is used as the main drive motor and the other as the auxiliary motor. The power module used to control the two motors is integrated and designed to reduce the packaging volume of the power module, improve the power density of the controller, and reduce the cost.

[0043] In the embodiment of the present invention, the shell is made of aluminum, and the shell is filled with glue to integrate the DC support capacitor and filter components, power module, current sensor, driver board, and fuse component with integrated magnetic ring. Compared with the existing DC support capacitor encapsulated in a plastic shell, the filter component is molded separately. The integrated solution can save the development of one set of plastic molds, reduce the number of molds for parts, simplify the assembly process, and improve assembly efficiency.

[0044] like Fig.10 As shown, the power module includes a copper plate heat sink, a first AC output interface and a second AC output interface, and a pinFin for dissipating heat is provided on the copper plate heat sink.

[0045] Specifically, Fig.10 As shown, the first AC output interface includes: U1 output phase A1 copper bar, V1 output phase A2 copper bar, W1 output phase A3 copper bar. The second AC output interface includes: U2 output phase B1 copper bar, V2 output phase B2 copper bar, W2 output phase B3 copper bar. The three copper bars of the first AC output interface are used to connect to a motor on a new energy vehicle, and the three copper bars of the second AC output interface are used to connect to another motor on a new energy vehicle.

[0046] Specifically, according to the performance requirements of different vehicles, the current parameters of the two motors on the new energy vehicle are determined to carry out the specific SiC / Si module packaging design, and the resulting power module is integrated into a copper plate heat sink.

[0047] like Figure 6As shown, the DC input interfaces of the power module are provided with: interface C1, interface C2, interface D1, interface D2, interface E1, interface E2, interface F1, interface F2, interface G1, interface G2, interface H1 and interface H2.

[0048] Figure 7 for Figure 6 Schematic cross-sectional view, each copper bar of the first AC output interface and the second AC output interface passes through a silicon steel sheet respectively, the chip of the current sensor extends into the silicon steel sheet, and the chip of the current sensor is arranged opposite to the copper bar. Six silicon steel sheets are injection molded in the bracket of the power module, the A1 copper bar, A2 copper bar and A3 copper bar of the first AC output interface pass through three silicon steel sheets respectively, and the B1 copper bar, B2 copper bar and B3 copper bar of the second AC output interface pass through another three silicon steel sheets respectively.

[0049] Specifically, Figure 8 Figure 1 is a schematic diagram of the structure of silicon steel sheets. Fig. 9 The current sensor chip at the bottom of the driver board extends into the silicon steel sheet. The silicon steel sheet changes the magnetic field distribution to increase the magnetic density near the chip. The chip uses the HALL principle to detect magnetic field changes, ensuring sampling speed and accuracy. This design not only helps to improve current detection accuracy, but also makes the entire structure more compact, further reducing the size of the controller and increasing power density. The silicon steel sheet is injection molded in the bracket of the power module.

[0050] like Figure 5 As shown, the power module is located at the upper end of the shell, the DC support capacitor and filter components are integrated at the lower end of the shell, a cooling water channel is formed between the power module and the shell, and a water channel sealing ring is set between the power module and the shell to implement IP67 protection design. There are 3 mounting feet on the outside of the shell for mechanical connection to the new energy vehicle.

[0051] Specifically, the DC support capacitor (X capacitor) and the filter component (X / Y capacitor) are integrated at the lower end of the housing. Fig.15 As shown, a DC positive input copper busbar interface L and a DC negative input copper busbar interface K are led out from the right side of the shell.

[0052] The upper part of the shell leads to 12 positive and negative output interfaces of the DC support capacitor: C1a / C2a, D1a / D2a, E1a / E2a, F1a / F2a, G1a / G2a, H1a / H2a.

[0053] Specifically, Fig.12 As shown, the leftmost end of the housing is provided with a cooling medium inlet M, and the rightmost end of the housing is provided with a cooling medium outlet N. The cooling medium inlet M is used to communicate with the cooling medium inlet on the new energy vehicle and is sealed by a sealing ring. The cooling medium outlet N is used to communicate with the cooling medium outlet on the new energy vehicle and is sealed by a sealing ring.

[0054] Specifically, Figure 6 , Fig.15 and Fig.17 As shown in the figure, the copper bars C1, C2, D1, D2, E1, E2, F1, F2, G1, G2, H1, H2 of the DC input end of the power module are connected to the copper bars C1a / C2a, D1a / D2a, E1a / E2a, F1a / F2a, G1a / G2a, H1a / H2a of the DC support capacitor output end respectively by laser welding. Compared with the existing screw connection, the stray inductance is effectively reduced, the electromagnetic interference can be reduced, and the stability and reliability of the system are improved.

[0055] The power module formed by the above welding is fixed on the aluminum shell and reaches the IP67 protection level through the water channel sealing ring. The heat sink material at the bottom of the power module is copper, and the surface of the heat sink is nickel-plated to form a nickel-plated layer. The heat sink increases the fluid heat exchange area through the PinFin heat dissipation column.

[0056] like Figure 4 As shown, in order to meet the diversity of the controller interface, there is a fuse component at the battery high voltage input interface to meet the two-way output (PTC / AC). Fig. 20 As shown, the fuse assembly integrates a fuse and a magnetic ring. The magnetic ring is installed at the front end of the bracket, the positive connection copper bar is injection molded in the bracket, one end of the fuse is fixed to the positive connection copper bar, and the other end is fixed to the bracket. The entire fuse assembly is fixed to the new energy vehicle through 3 bolt interfaces. At the input end of the battery high-voltage harness, there is a replaceable magnetic ring structure to facilitate early EMC testing and adjustment.

[0057] In the embodiment of the present invention, the fuse assembly is integrated with a power distribution unit (PDU). By integrating the PDU function, various interface requirements of new energy vehicles can be met.

[0058] The core module of the dual-motor controller for new energy vehicles according to the embodiment of the present invention integrates two power modules with different current capabilities, which brings the following advantages compared with the existing method of using two power modules with separate packages:

[0059] 1. The module integrates the driver board, power module, DC support capacitor, filter component, current sensor, PDU, etc., with simple assembly and low cost.

[0060] 2. Integrated design can reduce the use of external plastic brackets and busbar terminals.

[0061] 3. The integrated design can reduce the size of the radiator and the packaging volume of the module.

[0062] The present invention is described above by way of example in conjunction with the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-mentioned methods. As long as various non-substantial improvements are made using the method concept and technical solution of the present invention; or the above concept and technical solution of the present invention are directly applied to other occasions without improvement, they are all within the protection scope of the present invention.

Claims

1. The core module of the dual-motor controller for new energy vehicles is characterized by: It includes a shell and a DC support capacitor, a filter component, a power module and a fuse component integrated on the shell. The power module includes a power module, a current sensor and a drive board. The current sensor is integrated inside the power module, and the power module is connected to the DC support capacitor.

2. The core module of the dual-motor controller for new energy vehicles according to claim 1 is characterized in that: The DC support capacitor, the filter assembly and the housing are integrated into one by glue potting.

3. The core module of the dual-motor controller for new energy vehicles according to claim 1 is characterized in that: The power module comprises a copper plate radiator, on which a pinFin for radiating heat is arranged.

4. The core module of the dual-motor controller for new energy vehicles according to any one of claims 1 to 3, characterized in that: The DC support capacitor and the power module are connected by laser welding.

5. The core module of the dual-motor controller for new energy vehicles according to any one of claims 1 to 3, characterized in that: The power module includes a first AC output interface and a second AC output interface. Each copper busbar of the first AC output interface and the second AC output interface passes through a silicon steel sheet respectively. The chip of the current sensor extends into the silicon steel sheet. The chip of the current sensor is arranged opposite to the copper busbar.

6. The core module of the dual-motor controller for new energy vehicles according to claim 5 is characterized in that: The silicon steel sheet is injection-molded in the bracket of the power module.

7. The core module of the dual-motor controller for new energy vehicles according to any one of claims 1 to 6, characterized in that: The power module is located at the upper end of the shell, the DC support capacitor and the filter component are integrated at the lower end of the shell, a cooling water channel is formed between the power module and the shell, and a water channel sealing ring is arranged between the power module and the shell.

8. The core module of the dual-motor controller for new energy vehicles according to any one of claims 1 to 7, characterized in that: A cooling medium inlet is arranged at one end of the shell, and a cooling medium outlet is arranged at the other end of the shell.

9. The core module of the dual-motor controller for new energy vehicles according to any one of claims 1 to 8, characterized in that: The fuse assembly integrates a fuse and a magnetic ring, the magnetic ring is installed at the front end of the bracket, the positive electrode connecting copper bar is injection molded in the bracket, one end of the fuse is fixed on the positive electrode connecting copper bar, and the other end is fixed on the bracket.

10. The core module of the dual-motor controller for new energy vehicles according to claim 9 is characterized in that: The fuse assembly is integrated with a power distribution unit.

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