Small three-electric controller of new energy automobile

Abstract

The invention discloses a new energy automobile small three-electricity controller, which comprises a circuit board, field effect crystal MOS transistors arranged on the circuit board, a vehicle-mounted charger OBC module and a direct current converter DCDC module, a plurality of groups of MOS transistors are arranged at two opposite ends of the circuit board, and the OBC module and the DCDC module are positioned between the MOS transistors at the two ends; the small three-electric controller further comprises a cooling flow channel. The cooling flow channel comprises a bottom plate and a vertical shell wall arranged on the bottom plate. The vertical shell wall and the bottom plate form a cavity with an opening at one end, the cavity is used for accommodating an OBC module and a DCDC module, a plurality of surfaces of the OBC module and the DCDC module are in direct contact with the surface of the cooling flow channel, and the MOS tube is connected with the side surface of the vertical shell wall; the cooling flow channel can perform direct water cooling on multiple surfaces of the OBC module and the DCDC module, the heat dissipation efficiency is higher, the working temperature of the OBC module and the DCDC module can be effectively reduced, and the service life of a device is prolonged.

Description

Technical Field

[0001] The invention relates to the technical field of electric vehicle motor controllers, and in particular to a highly integrated small three-electric controller using surround water cooling. Background Art

[0002] The "small three electrics" for charging and distribution of new energy electric vehicles include: on-board charger OBC, DC converter DCDC and power distribution unit PDU. The small three electric controller usually includes MOS tube, i.e. field effect transistor, which is the core control device of the small three electric controller.

[0003] The motor controller of the small three-electric system for new energy electric vehicles generally includes MOS tubes, DC filters, AC filters, DC converter DCDC modules, on-board charger OBC transformers, resonant capacitors and other components. Among them, MOS tubes and OBC transformers generate high heat under continuous high-power and high-torque conditions. Traditional small three-electric controllers use water cooling to cool the MOS tubes, but the OBC transformer only uses heat conduction between thermal conductive glue and the shell to dissipate heat. The poor heat dissipation effect has become a shortcoming in improving the power limit of the small three-electric system. Summary of the invention

[0004] The purpose of the present invention is to provide a surround water-cooled small three-electric controller to solve the problem of poor heat dissipation effect of the small three-electric controller.

[0005] To achieve the above objectives, the technical solution of the present invention is:

[0006] A small three-electric controller for new energy vehicles comprises a circuit board, a field effect crystal MOS tube, an on-board charger OBC module and a direct current converter DCDC module arranged on the circuit board, multiple groups of the MOS tubes are arranged at opposite ends of the circuit board, and the OBC module and the DCDC module are located between the MOS tubes at the two ends; the small three-electric controller also comprises a cooling channel, the cooling channel comprises a bottom plate and a vertical shell wall arranged on the bottom plate, the bottom plate and the vertical shell wall are hollow inside, and the hollow inside of the bottom plate and the vertical shell wall is filled with coolant; the vertical shell wall and the bottom plate form a cavity with an opening at one end, the cavity is used to accommodate the OBC module and the DCDC module, multiple surfaces of the OBC module and the DCDC module are in direct contact with the surface of the cooling channel, and the MOS tube is connected to the side of the vertical shell wall.

[0007] Furthermore, the circuit board is located at the top and the bottom plate is located at the bottom, the MOS tube assembly, the OBC module, the DCDC module and the vertical shell wall are located between the circuit board and the bottom plate, the MOS tube assembly is located on the outside of a cavity formed by the vertical shell wall and the bottom plate with an opening at one end, and the OBC module and the DCDC module are located on the inside of a cavity formed by the vertical shell wall and the bottom plate with an opening at one end.

[0008] Furthermore, the top surfaces of the OBC module and the DCDC module are connected to the circuit board, and the bottom surfaces of the OBC module and the DCDC module are connected to the upper surface of the base plate.

[0009] Furthermore, three side surfaces of the OBC module are in contact with and connected to the inner side surface of the vertical shell wall, and the MOS tube assembly is connected to the outer side surface of the vertical shell wall.

[0010] Furthermore, the vertical shell wall includes an upper side surface and a lower side surface, a connecting plate is arranged between the right ends of the upper side surface and the lower side surface, the upper side surface, the lower side surface and the connecting plate are grooved, and a through flow channel for the flow of coolant is formed inside the upper side surface, the lower side surface and the connecting plate.

[0011] Furthermore, the left end of the lower side surface is connected to the water inlet of the coolant, and the left end of the upper side surface is connected to the water outlet of the coolant.

[0012] Furthermore, the vertical shell wall and the bottom plate form a flow channel with a U-shaped cross-section, the interior of the bottom plate is a hollow cavity, and a transverse partition is arranged inside the bottom plate along the flow direction of the coolant, and the transverse partition divides the interior of the bottom plate into two upper and lower cavities, the cavity located below is connected to the groove in the lower side surface to form a whole, and the cavity located above is connected to the groove in the upper side surface to form a whole; the cavity located below and the lower side surface form one of the vertical channels of the U-shaped flow channel, the groove in the connecting plate serves as the bottom connecting channel of the U-shaped flow channel, and the cavity located above and the upper side surface form another vertical channel of the U-shaped flow channel.

[0013] Furthermore, a longitudinal partition is provided on the upper surface of the bottom plate, and the longitudinal partition divides the cavity with an open end formed by the vertical shell wall and the bottom plate into two left and right cavities, and the left and right cavities respectively accommodate the OBC module and the DCDC module.

[0014] Furthermore, the vertical shell wall and the bottom plate form a cuboid with an opening at one end, the MOS tube is located outside the cuboid, and the OBC module and the DCDC module are located inside the cuboid.

[0015] The beneficial effects of the present invention are:

[0016] In the present invention, the MOS tube assembly is in close contact with the outer side surface of the vertical shell wall. Since a coolant is arranged in the vertical shell wall, the vertical shell wall can directly dissipate heat for the MOS tube assembly. The three side surfaces of the OBC module are in close contact with the inner side surface of the vertical shell wall, and the bottom surface of the OBC module is in close contact with the upper surface of the base plate. The two opposite side surfaces of the DCDC module are in close contact with the inner side surfaces of the side surfaces of the vertical shell wall, and the bottom surface of the DCDC module is connected to the upper surface of the base plate; a coolant is arranged in the internal cavity of the vertical shell wall and the base plate, so the cooling channel directly water-cools the four surfaces of the OBC module, namely, the three side surfaces and one bottom surface, and the cooling channel directly water-cools the three surfaces of the DCDC module, namely, the two side surfaces and one bottom surface. The direct water cooling of multiple surfaces makes the controller more efficient in heat dissipation. The present invention has a better heat dissipation effect on the OBC module and the DCDC module, can effectively reduce the operating temperature of the OBC module and the DCDC module, and improve the life of the controller. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 This is a schematic diagram of the exploded structure of the small three-electric controller module of the present invention.

[0018] Figure 2 It is a schematic diagram of the structure of the MOS tube, DCDC module and OBC transformer of the present invention.

[0019] Figure 3 It is a schematic diagram of the flow channel explosion structure of the present invention.

[0020] Figure 4 It is a schematic diagram of the vertical shell wall of the present invention.

[0021] Figure 5 This is a structural diagram of the MOS tube fixing method of the present invention.

[0022] Figure 6 This is a schematic diagram of the explosion structure of the small three-electric controller module of the present invention.

[0023] Figure 7 It is a three-dimensional diagram of the cooling channel of the present invention.

[0024] Figure 8 This is a bottom view of the cooling channel of the present invention.

[0025] Among them: circuit board 1; MOS tube 2; OBC module 3; DCDC module 4; vertical shell wall 5; upper side 51, lower side 52; connecting plate 53; bottom plate 6; water inlet 7; water outlet 8; internal horizontal partition 61; external longitudinal partition 62; flat plate 63; connecting plate 9; plug connector 91. DETAILED DESCRIPTION

[0026] In order to make the purpose, technical solutions and advantages of the invention clearer, the present invention is further described below with reference to the accompanying drawings.

[0027] Figure 1 This is an exploded diagram of the small three-electric controller of a new energy vehicle of the present invention. The controller includes a circuit board 1 and a MOS tube 2 as a main chip module. Figure 1 and Figure 5 As shown, four MOS tubes 2 are grouped together, three groups of MOS tubes 2 are arranged on one side of the circuit board 1, and one group of MOS tubes 2 is arranged on the other side of the circuit board 1 opposite to the one side, for a total of sixteen MOS tubes 2, which are clamped by springs.

[0028] MOS tube 2 is the core control device of the controller, and has a large heat dissipation capacity. MOS tube 2 is used as the main heat dissipation module, and the on-board charger OBC module 3 and the DC converter DCDC module 4 are used as secondary heat dissipation modules. The surrounding flow channel of the present invention cools the MOS tube 2, the on-board charger OBC module 3 and the DC converter DCDC module 4.

[0029] The OBC module 3 and the DCDC module 4 are installed side by side on the circuit board 1. The OBC module 3 and the DCDC module 4 are located in the middle of the MOS tubes 2 on both sides of the circuit board 1. The OBC module 3 and the DCDC module 4 are fixed to the circuit board 1 by encapsulating thermal conductive buffer glue. Specifically, the top surfaces of the OBC module 3 and the transformer module 4 are fixed to the circuit board 1.

[0030] The small three-electric controller of the present invention also includes a cooling channel, and the shell of the cooling channel includes a vertical shell wall 5 and a bottom plate 6. The vertical shell wall 5 and the bottom plate 6 are hollow inside, and the hollow inside of the vertical shell wall 5 and the bottom plate 6 is filled with coolant to cool the small three-electric controller.

[0031] Figure 2 It is a schematic diagram of the structure of the MOS tube 2, OBC module 3 and DCDC module 4 of the present invention, showing in detail the relative installation positions of the MOS tube assembly, the OBC module 3 and the DCDC module 4 and the fixing method of the MOS tube. Figure 3 This is a schematic diagram of the flow channel explosion structure of the present invention. The flow channel passes through the MOS tube 2 and the OBC module 3 and the DCDC module 4 to dissipate heat. Since the bottom of the OBC module 3 and the DCDC module 4 are filled with thermal conductive glue, the heat can be absorbed by the coolant in the flow channel through the thermal conductive glue. The bottom of the OBC module 3 and the DCDC module 4 are filled with thermal conductive glue so that the bottom of the OBC module 3 and the DCDC module 4 are fixed on the upper surface of the bottom plate 6.

[0032] like Figure 2 , Figure 3 , Figure 4As shown, the vertical shell wall 5 is arranged on the bottom plate 6. In practical applications, the bottom end of the vertical shell wall 5 can be a certain distance away from the end of the bottom plate 6, so that other components required for the work of the small three-electric system can be installed between the bottom end of the vertical shell wall 5 and the end of the bottom plate 6. The vertical shell wall 5 and the bottom plate 6 form a rectangular parallelepiped cavity with an open end, and the cavity is used to accommodate the OBC module 3 and the DCDC module 4.

[0033] The MOS tube assembly is located outside the side of the rectangular parallelepiped, and the OBC module 3 and the DCDC module 4 are both located in the rectangular parallelepiped cavity. The circuit board 1 is located at the top, the bottom plate 6 is located at the bottom, the MOS tube assembly, the OBC module 3, the DCDC module 4 and the vertical shell wall 5 are located between the circuit board 1 and the bottom plate 6, the MOS tube assembly is located outside the rectangular parallelepiped formed by the vertical shell wall 5 and the bottom plate 6, and the OBC module 3 and the DCDC module 4 are both located in the rectangular parallelepiped cavity formed by the vertical shell wall 5 and the bottom plate 6. Figure 6 As shown, the MOS tube assembly is in contact with and connected to the outer side of the vertical shell wall 5 , and the MOS tube assembly is closely attached to the outer side of the vertical shell wall 5 . Since a cooling channel is arranged in the vertical shell wall 5 , the vertical shell wall 5 can dissipate heat for the MOS tube assembly. Figure 5 This is a structural diagram of the MOS tube fixing method of the present invention. The MOS tube is pressed by a part with a 301 stainless steel spring structure so that it contacts the surface of the vertical shell wall 5 through the ceramic sheet. Specifically, the MOS tube is installed on the ceramic sheet, and the ceramic sheet contacts the vertical shell wall 5. Thermal grease is brushed between the MOS tube and the ceramic sheet, between the ceramic sheet and the vertical shell wall 5, and between the contact surface of the MOS tube and the vertical shell wall 5 to ensure that the MOS tube, the ceramic sheet, and the surface of the vertical shell wall 5 are fully in contact.

[0034] The top surfaces of the OBC module 3 and the DCDC module 4 are fixed on the circuit board 1, and the bottom surfaces of the OBC module 3 and the DCDC module 4 are arranged on the upper surface of the base plate 6. The bottom surfaces of the OBC module 3 and the DCDC module 4 are located in the rectangular cavity formed by the vertical shell wall 5 and the base plate 6. Since a cooling channel is arranged in the hollow interior of the base plate 6, the base plate 6 can dissipate heat for the OBC module 3 and the transformer module 4. The bottom of the OBC module 3 and the DCDC module 4 are filled with thermal conductive glue, and the heat can be absorbed by the cooling channel through the thermal conductive glue. About Figure 3 The flat plate 63 is welded to the bottom plate 6 by friction welding. The flat plate 63 is used as a cooling channel and seals the cooling channel.

[0035] like Figure 7 and Figure 8As shown, the vertical shell wall 5 includes an upper side surface 51 and a lower side surface 52, and a connecting plate 53 is arranged between the right ends of the upper side surface 51 and the lower side surface 52. The upper side surface 51, the lower side surface 52 and the connecting plate 53 are hollow inside, and a through flow channel is formed inside the upper side surface 51, the lower side surface 52 and the connecting plate 53. The upper side surface 51, the lower side surface 52 and the connecting plate 53 are groove-shaped inside to allow the coolant to flow inside the upper side surface 51, the lower side surface 52 and the connecting plate 53. The vertical shell wall 5 is hollow inside, and the vertical shell wall 5 is filled with coolant. One of the side surfaces of the OBC module 3 is close to the inner side surface of the connecting plate 53, so when the coolant passes through the connecting plate 53, the cooling channel can directly water-cool the side surface of the OBC module 3.

[0036] The left end of the lower side surface 52 is connected to the water inlet 7 of the coolant, and the left end of the upper side surface 51 is connected to the water outlet 8 of the coolant.

[0037] Cooling liquid is arranged inside the vertical shell wall 5 and the bottom plate 6. In a specific embodiment, the vertical shell wall 5 and the bottom plate 6 form a flow channel with a U-shaped cross section. The inside of the bottom plate 6 is a hollow cavity. In a specific embodiment, the inside of the bottom plate 6 is a hollow cuboid. An internal transverse partition 61 is arranged inside the bottom plate 6 along the flow direction of the cooling liquid. The internal transverse partition 61 divides the inside of the bottom plate 6 into two upper and lower cavities. The cavity located below is connected to the lower side 52 as a whole, and the cavity located above is connected to the upper side 51 as a whole. The cavity located below and the lower side 52 form one of the vertical channels of the U-shaped flow channel. The connecting plate 53 serves as the bottom connecting channel of the U-shaped flow channel. The cavity located above and the upper side 51 form another vertical channel of the U-shaped flow channel.

[0038] The vertical shell wall 5 and the bottom plate 6 form a rectangular cavity with an opening at one end. A connecting plate 9 can be set at the opening. A plug connector 91 of the controller is set on the connecting plate 9. The plug connector 91 is connected to the connector on the vehicle. One end of the water inlet 7 and the water outlet 8 can pass through the connecting plate 9.

[0039] like Figure 8 As shown, Figure 8 The arrow in the figure indicates the flow direction of the coolant. The coolant enters one of the vertical channels of the U-shaped flow channel from the water inlet 7, then flows into the bottom connecting channel of the U-shaped flow channel, and then flows into another vertical channel of the U-shaped flow channel from the bottom connecting channel, and finally flows out from the water outlet 8.

[0040] As a preferred embodiment of the present invention, an external longitudinal partition 62 may be provided on the upper surface of the base plate 6, and the external longitudinal partition 62 divides the rectangular cavity formed by the vertical shell wall 5 and the base plate 6 into two left and right cavities, wherein the left cavity is used to accommodate the DCDC module 4, and the right cavity is used to accommodate the OBC module 3.

[0041] The DCDC module 4 and the OBC module 3 are both located inside the rectangular cavity formed by the vertical shell wall 5 and the bottom plate 6, and coolant flows inside the vertical shell wall 5 and the bottom plate 6. The bottom surface of the DCDC module 4 is connected to the upper surface of the bottom plate 6, and the two opposite sides of the DCDC module 4 are close to the inner side of the side of the vertical shell wall 5. Therefore, when the coolant flows, the cooling channel directly water cools the three surfaces of the DCDC module 4, namely, two side surfaces and one bottom surface. The bottom surface of the OBC module 3 is connected to the upper surface of the bottom plate 6, and the OBC module is close to the bottom of the cooling channel with a U-shaped cross-section, so that the OBC module 3 has three side surfaces close to the inner side of the side of the vertical shell wall 5. Therefore, when the coolant flows, the cooling channel directly water cools the four surfaces of the OBC module 3, namely, three side surfaces and one bottom surface. Due to the different sizes of the OBC module 3 and the DCDC module 4, in order to make the sides of the OBC module 3 and the DCDC module 4 closely contact the vertical shell wall 5, the thickness of the vertical shell wall 5 can be increased at a local position of the vertical shell wall 5. Thermally conductive buffer glue may be filled between the side surfaces of the OBC module 3 and the DCDC module 4 and the vertical shell wall 5 to enhance the heat dissipation effect.

[0042] The present invention integrates the core components inside the small three-electric controller, including the DCDC module and the OBC transformer module, into a controller module. The MOS tube of the controller serves as the main heat dissipation module, and the DCDC module and the OBC transformer module serve as the secondary heat dissipation module. The cooling channel of the small three-electric controller in the present invention adopts a channel with a U-shaped cross-section. The cooling flow passes through the MOS tube assembly and the area where the DCDC module and the OBC module are located. In addition to water cooling the MOS tube assembly, the present invention also water cools the DCDC module and the OBC, and retains the use of thermal conductive glue to conduct heat between the shell walls by retaining the DCDC module and the OBC module. Therefore, the cooling channel of the present invention directly water cools the four surfaces of the OBC module and directly water cools the three surfaces of the DCDC module. The other surfaces of the DCDC module and the OBC module can be heat-dissipated by conduction through the thermal conductive glue. The heat dissipation efficiency of the whole scheme is higher, and the heat dissipation effect for the DCDC module and the OBC transformer module is better, which can effectively reduce the operating temperature of the DCDC module and the OBC transformer module and improve the service life.

[0043] The small three-electric controller module of the present invention is a highly integrated small three-electric controller of a surround water-cooled MOS tube, a DCDC module, and an OBC module, which can simultaneously meet the performance requirements of high ambient temperature and continuous high power and high torque, and all sub-modules of the module can be designed as a platform, greatly improving the heat dissipation effect and power density.

[0044] The small three-electric controller module of the present invention can be used as a finished product alone, or it can be installed in the motor and electronic control integrated shell wall for integrated use. It is flexible in application and greatly meets the requirements of high power density, miniaturization and lightweight of the electric drive assembly system.

[0045] Finally, it should be noted that the contents not described in detail in this specification belong to the prior art known to professional and technical personnel in this field. The above description is only the preferred embodiment of the present invention and is not used to limit the present invention. Although the present invention is described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions recorded in the aforementioned embodiments, or to replace some of the technical features therein by equivalents. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A small three-electric controller for a new energy vehicle, comprising a circuit board (1), a field effect transistor MOS tube (2) arranged on the circuit board (1), an on-board charger OBC module (3) and a direct current converter DCDC module (4), characterized in that: A plurality of groups of MOS tubes (2) are arranged at two opposite ends of a circuit board (1), and an OBC module (3) and a DCDC module (4) are located between the MOS tubes (2) at the two ends; the small three-electric controller further comprises a cooling channel, the cooling channel comprising a base plate (6) and a vertical shell wall (5) arranged on the base plate (6), the base plate (6) and the vertical shell wall (5) are hollow inside, and the hollow inside of the base plate (6) and the vertical shell wall (5) is filled with cooling liquid; the vertical shell wall (5) and the base plate (6) form a cavity with an opening at one end, the cavity is used to accommodate the OBC module (3) and the DCDC module (4), multiple surfaces of the OBC module (3) and the DCDC module (4) are in direct contact with the surface of the cooling channel, and the MOS tube (2) is connected to the side of the vertical shell wall (5).

2. A small three-electric controller for new energy vehicles according to claim 1, characterized in that: The circuit board (1) is located at the top and the bottom plate (6) is located at the bottom; the MOS tube assembly, the OBC module (3), the DCDC module (4) and the vertical shell wall (5) are located between the circuit board (1) and the bottom plate (6); the MOS tube assembly is located outside a cavity formed by the vertical shell wall (5) and the bottom plate (6) and one end of which is an opening; and the OBC module (3) and the DCDC module (4) are located inside a cavity formed by the vertical shell wall (5) and the bottom plate (6) and one end of which is an opening.

3. A small three-electric controller for new energy vehicles according to claim 1, characterized in that: The top surfaces of the OBC module (3) and the DCDC module (4) are connected to the circuit board (1), and the bottom surfaces of the OBC module (3) and the DCDC module (4) are connected to the upper surface of the base plate (6).

4. A small three-electric controller for new energy vehicles according to claim 1, characterized in that: Three side surfaces of the OBC module (3) are connected to the inner side surface of the vertical shell wall (5), and the MOS tube assembly is connected to the outer side surface of the vertical shell wall (5).

5. A small three-electric controller for new energy vehicles according to claim 1, characterized in that: The vertical shell wall (5) comprises an upper side surface (51) and a lower side surface (52); a connecting plate (53) is arranged between the right ends of the upper side surface (51) and the lower side surface (52); the upper side surface (51), the lower side surface (52) and the connecting plate (53) have grooves inside, and a through flow channel for the flow of cooling liquid is formed inside the upper side surface (51), the lower side surface (52) and the connecting plate (53).

6. A small three-electric controller for new energy vehicles according to claim 5, characterized in that: The left end of the lower side surface (52) is connected to a water inlet (7) of the cooling liquid, and the left end of the upper side surface (51) is connected to a water outlet (8) of the cooling liquid.

7. A small three-electric controller for new energy vehicles according to claim 1, characterized in that: The vertical shell wall (5) and the bottom plate (6) form a flow channel with a U-shaped cross section. The interior of the bottom plate (6) is a hollow cavity. An internal transverse partition (61) is arranged inside the bottom plate (6) along the flow direction of the coolant. The internal transverse partition (61) divides the interior of the bottom plate (6) into two upper and lower cavities. The cavity located at the bottom is connected to the groove in the lower side (52) as a whole, and the cavity located at the top is connected to the groove in the upper side (51) as a whole; the cavity located at the bottom and the lower side (52) form one vertical channel of the U-shaped flow channel, the groove in the connecting plate (53) serves as the bottom connecting channel of the U-shaped flow channel, and the cavity located at the top and the upper side (51) form another vertical channel of the U-shaped flow channel.

8. A small three-electric controller for new energy vehicles according to claim 1, characterized in that: An external longitudinal partition (62) is provided on the upper surface of the base plate (6), and the external longitudinal partition (62) divides a cavity with an open end formed by the vertical shell wall (5) and the base plate (6) into two left and right cavities, and the left and right cavities respectively accommodate the OBC module (3) and the DCDC module (4).

9. A small three-electric controller for new energy vehicles according to claim 1, characterized in that: The vertical shell wall (5) and the bottom plate (6) form a rectangular parallelepiped with an opening at one end; the MOS tube (2) is located outside the rectangular parallelepiped; and the OBC module (3) and the DCDC module (4) are located inside the rectangular parallelepiped.

10. A small three-electric controller for new energy vehicles according to claim 1, characterized in that: Three groups of MOS tubes (2) are arranged on one side of the circuit board (1), and one group of MOS tubes (2) is arranged on the other side of the circuit board (1) opposite to the one side.

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