Single-motor controller system for new energy automobile
By designing a single motor controller system for new energy vehicles, the bloat and inconvenience of traditional motor controllers on small and medium-sized power and simple structure machines is solved, and compact and efficient motor control and energy management is achieved, which is suitable for 500V and 800V new energy vehicle battery systems.
Patent Information
- Application Number
- CN202510153816.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-02-12
- Publication Date
- 2025-04-08
AI Technical Summary
Due to the complexity and huge volume of traditional new energy vehicle motor controllers, new energy vehicles appear bloated on small and medium-sized power and simple structure machines, increasing energy loss and cost, and bringing inconvenience to installation and maintenance.
A single motor controller system for new energy vehicles was designed, including control board modules, drive board modules, bus capacitor and power device modules, discharge and Y capacitor board modules, and motor modules. Through the connection and configuration of these modules, efficient control and energy management of the motor are achieved.
It realizes a small and lightweight controller system, reduces faults caused by wiring harness, is adapted to 500V and 800V new energy vehicle battery systems, and provides rich expansion interfaces, improving the flexibility and applicability of the system.
Smart Images
Figure CN119787922A_ABST
Abstract
Description
Technical Field
[0001] The invention belongs to the technical field of single motor controller systems, and relates to a single motor controller system for new energy vehicles. Background Art
[0002] In the field of new energy vehicles, motor controllers play a pivotal role and are the core source of power for new energy vehicles. They provide stable and efficient drive for motors by precisely controlling parameters such as current and voltage, which directly determines the power performance of new energy vehicles, such as acceleration capability and maximum speed. However, traditional motor controllers are generally installed in the assembly of new energy vehicles. This assembly usually integrates a variety of complex components and systems, and is a relatively large and comprehensive whole. For some machines that only require small and medium power and have relatively simple structures, if they are to be assembled into new energy vehicle assemblies, they will face many problems. On the one hand, due to the complexity and large size of the assembly, these machines will appear extremely bloated in appearance and spatial layout, destroying the overall simplicity and compactness; on the other hand, in the actual operation process, it may cause unnecessary energy loss and cost increase, and also bring inconvenience to installation, maintenance and other operations. Summary of the invention
[0003] In order to solve the problems existing in the background technology, the present invention proposes a single motor controller system for new energy vehicles.
[0004] In order to achieve the above object, the technical solution adopted by the present invention is as follows: A single motor controller system for new energy vehicles, comprising: a control board module, a drive board module, a bus capacitor and power device module, a discharge and Y capacitor board module, and a motor module; The output end of the control board module is connected to the input end of the driving board module, the output end of the driving board module is connected to the input end of the bus capacitor and power device module, the output end of the bus capacitor and power device module is connected to the motor module, and the output end of the discharge and Y capacitor board module is connected to the input end of the bus capacitor and power device module.
[0005] Furthermore, the control board module includes: an external interface module, a BUCK power module, a CAN transceiver chip module, an IO expansion module, a delayed power-off module, a motor temperature sampling module, an MCU module, an overcurrent protection circuit module, a Hall current sampling module, and a PWM port; The external interface module is respectively connected to the BUCK power module, the CAN transceiver chip module, the IO expansion module, the delayed power-off module, and the motor temperature sampling module; the MCU module is respectively connected to the output end of the BUCK module, the output end of the motor temperature sampling module, the output end of the overcurrent protection circuit module, and the output end of the Hall current sampling module; the output end of the Hall current sampling module is connected to the input end of the overcurrent protection circuit; The PWM port outputs a PWM signal. The control board module is the core of the controller system, in which the control board module is responsible for the calculations required to control the motor module. The control board module receives the current signal amplified by the operational amplifier and the decoded resolver signal, and after calculation, sends a PWM signal to the drive board module.
[0006] Further, the PWM port is connected to a driver board module; The driving board module includes an isolation driving optocoupler module, a battery power port, a flyback power module, and a fault signal port; The output end of the PWM port is connected to the isolation drive optocoupler module, the MCU module of the control board module is connected to the input end of the battery power port, the output end of the battery power port is connected to the input end of the flyback power module, the output end of the flyback power module is connected to the isolation drive optocoupler module, and the fault signal port of the isolation drive optocoupler module is connected to the control board module.
[0007] The driver board module provides driving current for this system through the isolated driving optocoupler module.
[0008] Further, the bus capacitor and power device module includes a positive bus port, a negative bus port, a U-phase port, a V-phase port, a W-phase port, a power capacitor, and an IGBT module; The output end of the isolation drive optocoupler module is connected to the input end of the IGBT module, the output end of the positive bus port and the output end of the negative bus port are connected to the input end of the IGBT module, the output end of the IGBT module is connected to the U phase port, the V phase port, and the W phase port, one end of the power capacitor is connected between the positive bus port and the IGBT module, and the other end of the power capacitor is connected between the negative bus port and the IGBT module; The IGBT module integrates six-unit switch tubes, that is, six MOS tubes connected to each other, and the U-phase port, the V-phase port, and the W-phase port generally refer to the three phases of the three-phase alternating current; The power capacitor can filter out most of the AC components when the IGBT module is switched, and can absorb the peak voltage and high pulse current on the bus.
[0009] Further, the discharge and Y capacitor board module includes a discharge resistor, a first Y capacitor, a second Y capacitor, and a housing ground; One end of the discharge resistor is connected to the positive bus port and the first Y capacitor, the other end of the discharge resistor is connected to the negative bus port and the second Y capacitor, and the housing ground is connected between the first Y capacitor and the second Y capacitor; The discharge and Y capacitor board modules can consume the power of the busbar within 3 minutes and restore it to a power-free state.
[0010] Compared with the prior art, the present invention has the following beneficial effects: Compared with the traditional motor controller system, this motor controller system has some extended interfaces that can be used independently of the new energy vehicle controller, such as external analog quantity sampling, high and low level output control, high and low level input control, circuits that can drive external relays, throttle power supply and other interfaces.
[0011] This controller is compact and lightweight while ensuring safety and heat dissipation. It has internal wire harness processing to reduce faults caused by wire harnesses and is compatible with 500V and 800V new energy vehicle battery systems. BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Figure 1 This is a structural block diagram of a single motor controller system for new energy vehicles of the present invention; Figure 2 This is a circuit topology diagram of a single motor controller system for new energy vehicles of the present invention; Figure 3 It is a schematic diagram of the control panel module of the present invention; Figure 4 It is a schematic diagram of the drive board module of the present invention; Figure 5 It is a schematic diagram of the bus capacitor and power device module of the present invention; Figure 6 It is a diagram of the discharge and Y capacitor board module of the present invention. DETAILED DESCRIPTION
[0013] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.
[0014] like Figure 1-Figure 6As shown, the technical solution adopted by the present invention is as follows: a single motor controller system for new energy vehicles, including: a control board module, a drive board module, a bus capacitor and power device module, a discharge and Y capacitor board module, and a motor module.
[0015] The output end of the control board module is connected to the input end of the driving board module, the output end of the driving board module is connected to the input end of the bus capacitor and power device module, the output end of the bus capacitor and power device module is connected to the motor module, and the output end of the discharge and Y capacitor board module is connected to the input end of the bus capacitor and power device module.
[0016] Furthermore, the control board module includes: an external interface module, a BUCK power supply module, a CAN transceiver chip module, an IO expansion module, a delayed power-off module, a motor temperature sampling module, an MCU module, an overcurrent protection circuit module, a Hall current sampling module, and a PWM port.
[0017] The external interface module is respectively connected to the BUCK power module, the CAN transceiver chip module, the IO extension module, the delayed power-off module, and the motor temperature sampling module; the MCU module is respectively connected to the output end of the BUCK module, the output end of the motor temperature sampling module, the output end of the overcurrent protection circuit module, and the output end of the Hall current sampling module; the output end of the Hall current sampling module is connected to the input end of the overcurrent protection circuit.
[0018] The PWM port outputs a PWM signal, and the PWM port is connected to a driving board module.
[0019] The control board module is the core of this controller system, in which the control board module is responsible for the calculations required for motor control. The control board module receives the current signal amplified by the operational amplifier on the board and the decoded resolver signal, and after calculation, sends a PWM signal to the driver board. The driver board controls the switch of the IGBT module through the PWM signal, thereby controlling the motor.
[0020] The control panel module is also equipped with an external interface module. While controlling the motor, it can also receive external analog quantities, high and low level judgments, and relay control. It can also control external devices or receive signals through the external interface module. The control panel module is also equipped with a delayed power-off function for new energy vehicles, which can delay the vehicle from powering off after the driver turns the key. At the same time, the control panel module is also equipped with a function to step down the battery voltage to provide it for external power supply and internal power supply.
[0021] The driving board module includes an isolation driving optical coupling module, a battery power port, a flyback power module, and a fault signal port.
[0022] The output end of the PWM port is connected to the isolation drive optocoupler module, the MCU module of the control board module is connected to the input end of the battery power port, the output end of the battery power port is connected to the input end of the flyback power module, the output end of the flyback power module is connected to the isolation drive optocoupler module, and the fault signal port of the isolation drive optocoupler module is connected to the control board module.
[0023] The isolated drive optocoupler module on the driver board module can provide drive current for driving the IGBT module. Because the voltage and current of the PWM signal output by the control board module are not enough to drive the IGBT module, it needs to pass through the isolated drive optocoupler module to allow the isolated drive optocoupler module to provide voltage and current. In this way, the stable operation of the IGBT module can be guaranteed. Otherwise, the switching state of the IGBT module enters the amplification area, which will cause excessive loss of the IGBT module and eventually damage the IGBT module. The driver board module also has an operational amplifier, which can amplify the voltage signal of the temperature sensor in the IGBT module and give it to the control board module to judge the temperature of the IGBT module. At the same time, the power supply required by the isolated drive optocoupler module is provided by the flyback power supply module. The flyback power supply module can stably provide the voltage and current required by the six units of the IGBT.
[0024] The bus capacitor and power device module includes a positive bus port, a negative bus port, a U-phase port, a V-phase port, a W-phase port, a power capacitor, and an IGBT module.
[0025] The output end of the isolation drive optocoupler module is connected to the input end of the IGBT module, the output end of the positive bus port and the output end of the negative bus port are connected to the input end of the IGBT module, the output end of the IGBT module is connected to the U-phase port, the V-phase port, and the W-phase port, one end of the power capacitor is connected between the positive bus port and the IGBT module, and the other end of the power capacitor is connected between the negative bus port and the IGBT module.
[0026] The IGBT module integrates six switch units, namely six MOS tubes connected to each other. The U-phase port, the V-phase port, and the W-phase port usually refer to the three phases of the three-phase alternating current.
[0027] The power capacitor can filter out most of the AC components when the IGBT module is switched on and off. At the same time, it can absorb the peak voltage on the bus to prevent the IGBT module from being damaged by the peak voltage. It can also absorb the high pulse current on the bus to prevent it from affecting the control board module.
[0028] The discharge and Y capacitor board module includes a discharge resistor, a first Y capacitor, a second Y capacitor, and a shell ground.
[0029] One end of the discharge resistor is connected to the positive bus port and the first Y capacitor, the other end of the discharge resistor is connected to the negative bus port and the second Y capacitor, and the housing ground is connected between the first Y capacitor and the second Y capacitor.
[0030] The discharge and Y capacitor board module can consume the power of the bus within 3 minutes, restoring it to a non-powered state, preventing maintenance personnel from accidentally touching it during disassembly and installation and causing electric shock. The first Y capacitor and the second Y capacitor can reduce the high-frequency noise on the bus and suppress common-mode interference.
[0031] The function of the control board module is to be responsible for external communication and collecting output current, as well as controlling the drive board module. The drive board module controls the IGBT module, and the IGBT module outputs the corresponding current. The current samples the voltage signal through the Hall current sampling module and feeds it back to the control board module for reception and analysis. The control board module then outputs the corresponding control signal to the drive board module. In this way, the motor module can be controlled. The power capacitor is placed between the IGBT module and the busbar, which can filter out the ripple generated by the IGBT module during operation, suppress the peak voltage, and avoid damage to the IGBT module. The discharge and Y capacitor board module can discharge the high voltage after the system is powered off, so that the system can enter the safe operation stage as soon as possible. The first Y capacitor and the second Y capacitor can filter out the interference signal on the busbar.
[0032] This solution is applicable to many different types of vehicles on the market, from heavy trucks to light trucks and agricultural machinery. Due to its small size and light weight, it can be placed above the motor to form a two-in-one motor and electronic control system, and can be mounted on the vehicle alone for use. This can be used as an auxiliary motor controller for heavy trucks, or as a motor controller for agricultural machinery.
[0033] Compared with traditional new energy vehicle assemblies, this controller system can be used independently of the new energy vehicle controller. It has abundant external expansion interfaces, which can collect external signal analog quantities, external high and low levels, and control external high and low levels and relays. It also has a power supply that can supply power to the outside.
[0034] Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments, or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.
Claims
1. A single motor controller system for new energy vehicles, characterized in that: Including: control board module, drive board module, bus capacitor and power device module, discharge and Y capacitor board module, motor module; The output end of the control board module is connected to the input end of the driving board module, the output end of the driving board module is connected to the input end of the bus capacitor and power device module, the output end of the bus capacitor and power device module is connected to the motor module, and the output end of the discharge and Y capacitor board module is connected to the input end of the bus capacitor and power device module.
2. A single motor controller system for new energy vehicles according to claim 1, characterized in that: The control board module includes: external interface module, BUCK power module, CAN transceiver chip module, IO expansion module, delayed power-off module, motor temperature sampling module, MCU module, overcurrent protection circuit module, Hall current sampling module, and PWM port; The external interface module is respectively connected to the BUCK power module, the CAN transceiver chip module, the IO expansion module, the delayed power-off module, and the motor temperature sampling module; the MCU module is respectively connected to the output end of the BUCK module, the output end of the motor temperature sampling module, the output end of the overcurrent protection circuit module, and the output end of the Hall current sampling module; the output end of the Hall current sampling module is connected to the input end of the overcurrent protection circuit; The PWM port outputs a PWM signal, and the control board module receives the current signal amplified by the operational amplifier and the decoded resolver signal, and sends out a PWM signal after calculation.
3. A single motor controller system for new energy vehicles according to claim 2, characterized in that: The PWM port is connected to a driver board module; The driving board module includes an isolation driving optocoupler module, a battery power port, a flyback power module, and a fault signal port; The output end of the PWM port is connected to the isolation drive optocoupler module, the MCU module of the control board module is connected to the input end of the battery power port, the output end of the battery power port is connected to the input end of the flyback power module, the output end of the flyback power module is connected to the isolation drive optocoupler module, and the fault signal port of the isolation drive optocoupler module is connected to the control board module.
4. A single motor controller system for new energy vehicles according to claim 3, characterized in that: The bus capacitor and power device module includes a positive bus port, a negative bus port, a U-phase port, a V-phase port, a W-phase port, a power capacitor, and an IGBT module; The output end of the isolation drive optocoupler module is connected to the IGBT module, the output end of the positive bus port and the output end of the negative bus port are connected to the input end of the IGBT module, the output end of the IGBT module is connected to the U phase port, the V phase port, and the W phase port, one end of the power capacitor is connected between the positive bus port and the IGBT module, and the other end of the power capacitor is connected between the negative bus port and the IGBT module; The IGBT module integrates six-unit switch tubes, which are formed by six MOS tubes connected to each other. The U-phase port, the V-phase port, and the W-phase port refer to the three phases of the three-phase alternating current; The power capacitor filters out part of the AC component of the IGBT module when it is switched on and off, and can absorb the peak voltage on the bus and the high pulse current on the bus.
5. A single motor controller system for new energy vehicles according to claim 4, characterized in that: The discharge and Y capacitor board module includes a discharge resistor, a first Y capacitor, a second Y capacitor, and a shell ground; One end of the discharge resistor is connected to the positive bus port and the first Y capacitor, the other end of the discharge resistor is connected to the negative bus port and the second Y capacitor, and the housing ground is connected between the first Y capacitor and the second Y capacitor.