Motor controller, electric drive assembly and vehicle

Abstract

The invention relates to the technical field of motor control, and particularly discloses a motor controller, an electric drive assembly and a vehicle. The motor controller comprises a controller shell and an inverter brick assembly; the inverter brick assembly comprises a shell, a water cooling plate, a filtering assembly and a capacitor assembly, the shell is installed in the controller shell and comprises a first shell part and a second shell part, the second shell part is connected with the first shell part in the first direction, the first shell part is provided with a first containing cavity and a second containing cavity, and the second shell part is provided with a third containing cavity. Specifically, the first containing cavities and the third containing cavities are arranged at intervals in the first direction, and the first containing cavities and the second containing cavities are arranged at intervals in the second direction. The water cooling plate is arranged in the first accommodating cavity, one part of the filtering assembly and the capacitor assembly are integrally encapsulated in the second accommodating cavity, and the other part of the filtering assembly is independently encapsulated in the third accommodating cavity. The motor controller is small in size, and the production difficulty and cost can be reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of motor control, and in particular to a motor controller, an electric drive assembly and a vehicle. Background Art

[0002] In the motor controller structure, the core device modules include power devices, water-cooling plates for heat dissipation of power devices, capacitor components and control drive boards; this part of the device structure is designed into an integrated assembly module, called an inverter brick assembly. The inverter brick assembly can be adapted to various types of vehicles to meet the requirements of universality and modular design.

[0003] However, most of the current inverter brick assemblies have problems such as large size, difficulty in production and high cost. Summary of the invention

[0004] The present application provides a motor controller, an electric drive assembly and a vehicle. The motor controller is small in size and can reduce production difficulty and cost.

[0005] In order to solve the above technical problems, a technical solution adopted in the present application is: to provide a motor controller, which includes a controller housing and an inverter brick assembly; the inverter brick assembly includes a housing, a water-cooling plate, a filter component and a capacitor component, the housing is installed in the controller housing, the housing includes a first housing part and a second housing part, along the first direction, the second housing part is connected to the first housing part, the first housing part is provided with a first accommodating chamber and a second accommodating chamber, and the second housing part is provided with a third accommodating chamber; wherein, along the first direction, the second accommodating chamber and the third accommodating chamber are arranged at intervals, and along the second direction, the first accommodating chamber and the second accommodating chamber are arranged at intervals, the first direction is perpendicular to the second direction, and the second direction is parallel to the arrangement direction of the housing and the controller housing; the water-cooling plate is arranged in the first accommodating chamber, a part of the filter component and the capacitor component are integrated and encapsulated in the second accommodating chamber, and another part of the filter component is separately encapsulated in the third accommodating chamber.

[0006] Among them, the filter component includes a nanocrystalline magnetic ring; the inverter brick assembly also includes a sealing component, along the third direction, the third accommodating cavity is provided with two opposite openings, the nanocrystalline magnetic ring passes through one opening and is sealed in the third accommodating cavity, and the sealing component cover is provided at the other opening; wherein the third direction is perpendicular to both the first direction and the second direction.

[0007] Among them, the filter component also includes an injection molded body, which is connected and fixed to the side of the nanocrystalline magnetic ring facing the opening; the sealing component includes a first cover plate and a second cover plate, the first cover plate is provided with a notch, and along the second direction, the notch includes a first sealing port and a second sealing port that are interconnected; wherein, after the injection molded body passes through the third accommodating cavity, the first cover plate covers the opening, so that the injection molded body passes through the second sealing port and is located in the first sealing port, and the second cover plate is covered in the second sealing port.

[0008] Among them, the inverter brick assembly also includes a Hall element, a control and drive integrated board and a power device. Along the second direction, the Hall element, the control and drive integrated board and the power device are arranged in sequence above the water cooling plate.

[0009] Among them, the first accommodating cavity is provided with two side walls opposite to each other along the first direction, and the bottom of the side walls is provided with a liquid inlet interface and a liquid outlet interface. Along the second direction, at least part of the liquid inlet interface and at least part of the liquid outlet interface are located above the water cooling plate.

[0010] A cooling channel is formed between the power device and the shell, and the cooling channel is connected to a liquid inlet interface and a liquid outlet interface.

[0011] Among them, a coolant inlet and a coolant outlet are arranged in the controller housing, the liquid inlet interface is connected with the coolant inlet, and the liquid outlet interface is connected with the coolant outlet.

[0012] The present application also includes a second technical solution, which provides an electric drive assembly, including the above-mentioned motor controller and a motor housing and a reducer housing arranged in sequence along a first direction, wherein the motor housing, the reducer housing and the controller housing are integrated by die-casting.

[0013] Among them, the electric drive assembly also includes a motor, a reducer and a high-voltage wiring harness. The motor is arranged in the motor housing, the reducer is arranged in the reducer housing, and the high-voltage wiring harness passes through the controller housing and is electrically connected to the inverter brick assembly.

[0014] The present application also includes a third technical solution, which provides a vehicle including the above-mentioned electric drive assembly.

[0015] The beneficial effects of the present application are as follows: Different from the prior art, the motor controller provided by the present application includes a controller housing and an inverter brick assembly; the inverter brick assembly includes a housing, a water-cooling plate, a filter assembly and a capacitor assembly, the housing is installed in the controller housing, the housing includes a first housing portion and a second housing portion, along the first direction, the second housing portion is connected to the first housing portion, the first housing portion is provided with a first accommodating chamber and a second accommodating chamber, and the second housing portion is provided with a third accommodating chamber. Specifically, along the first direction, the first accommodating chamber and the third accommodating chamber are arranged at intervals, along the second direction, the first accommodating chamber and the second accommodating chamber are arranged at intervals, the first direction is perpendicular to the second direction, and the second direction is parallel to the arrangement direction of the housing and the controller housing; the water-cooling plate is arranged in the first accommodating chamber, a part of the filter assembly is integrated and potted in the second accommodating chamber together with the capacitor assembly, and another part of the filter assembly is separately potted in the third accommodating chamber. The present application realizes modularization by making the capacitor component, filter component and water cooling plate share a housing, while reducing the volume of the inverter brick assembly and saving the internal space of the motor controller. In addition, since the capacitor component and the filter component are integrated in the housing by potting, the production difficulty and cost are reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the description of the embodiments are briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative work, among which:

[0017] Figure 1 1 is a schematic diagram of the structure of an embodiment of a motor controller of the present application, wherein the motor controller comprises an inverter brick assembly, and the inverter brick assembly comprises a housing, a filter assembly and a capacitor assembly;

[0018] Figure 2 yes Figure 1 A schematic diagram of the structure of the middle housing, capacitor assembly and filter assembly;

[0019] Figure 3 yes Figure 1 A schematic diagram of the structure of the middle housing and the filter assembly;

[0020] Figure 4 yes Figure 1 Schematic diagram of the structure of the filter component;

[0021] Figure 5 yes Figure 1 The schematic diagram of the overall assembly of the inverter brick assembly;

[0022] Figure 6 yes Figure 1 Schematic diagram of the structure of the middle inverter brick assembly after overall assembly;

[0023] Figure 7 yes Figure 6 The structural diagram of the AA section of the middle inverter brick assembly;

[0024] Figure 8 It is a structural schematic diagram of an embodiment of an electric drive assembly of the present application.

[0025] Reference numerals: 1, controller housing; 11, coolant inlet; 12, coolant outlet; 13, coolant inlet hole; 14, coolant outlet hole; 15, through hole; 2, inverter brick assembly; 21, housing; 211, first housing portion; 2111, first accommodating chamber; 2112, second accommodating chamber; 2113, liquid inlet interface; 2114, liquid outlet interface; 212, second housing portion; 2121, third accommodating chamber; 2122, opening; 2123, slide; 213, liquid inlet channel; 2131, liquid inlet; 214, liquid outlet channel; 2141, liquid outlet; 22, water cooling plate; 23, filter assembly; 231, nanocrystalline magnetic ring; 232, injection molding; 2321, third sealing groove; 233, ferrite magnetic ring; 234, first copper busbar; 235, second copper busbar; 236, first circuit board; 237, second circuit board; 238. Input port; 239. Output port; 24. Capacitor assembly; 241. Connecting busbar; 242. Capacitor terminal; 25. Sealing assembly; 251. First cover plate; 252. Second cover plate; 253. Notch; 2531. First sealing port; 2532. Second sealing port; 2533. First sealing groove; 2534. Second sealing groove; 2521. Fourth sealing groove; 26. Hall element; 261. Three-phase Hall; 262. Three-phase copper busbar; 27. Control drive integrated board; 28. Power device; 281. Connecting terminal; 282. Output terminal; 29. ​​Cooling channel; 3. Busbar copper busbar assembly; 31. Input copper busbar; 32. Output copper busbar; 4. Upper cover; 20. Motor housing; 30. Reducer housing; 40. High-voltage wiring harness; 50. Three-phase line transfer copper busbar; 10. Motor controller; 100. Electric drive assembly. DETAILED DESCRIPTION

[0026] In order to make the above-mentioned purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are described in detail below in conjunction with the accompanying drawings. It is to be understood that the specific embodiments described herein are only used to explain the present application, rather than to limit the present application. It should also be noted that, for ease of description, only some structures related to the present application are shown in the accompanying drawings, rather than all structures. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application.

[0027] Reference to "embodiments" herein means that a particular feature, structure, or characteristic described in conjunction with the embodiments may be included in at least one embodiment of the present application. The appearance of the phrase in various locations in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment that is mutually exclusive with other embodiments. It is explicitly and implicitly understood by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0028] In the description of this application, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of this application, "plurality" means two or more, unless otherwise clearly and specifically defined.

[0029] In the description of this application, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection, an electrical connection, or mutual communication; it can be a direct connection, or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0030] Please refer to Figure 1 and Figure 2 , Figure 1 is a structural diagram of an embodiment of a motor controller provided by the present application, Figure 2 yes Figure 1In one aspect of the present application, a motor controller 10 is provided, which includes a controller housing 1 and an inverter brick assembly 2, the inverter brick assembly 2 includes a housing 21, a water-cooling plate 22, a filter assembly 23 and a capacitor assembly 24, the housing 21 is installed in the controller housing 1, the housing 21 includes a first housing portion 211 and a second housing portion 212, along the first direction D1, the second housing portion 212 is connected to the first housing portion 211, the first housing portion 211 is provided with a first accommodating cavity 2111 and a second accommodating cavity 2112, and the second housing portion 212 is provided with a third accommodating cavity 2121. Specifically, along the first direction D1, the second accommodating chamber 2112 and the third accommodating chamber 2121 are arranged at intervals, and along the second direction D2, the first accommodating chamber 2111 and the second accommodating chamber 2112 are arranged at intervals, the first direction D1 is perpendicular to the second direction D2, and the second direction D2 and the arrangement direction of the housing 21 and the controller housing 1 are parallel, the water-cooling plate 22 is arranged in the first accommodating chamber 2111, a part of the filter component 23 is integrated and potted in the second accommodating chamber 2112 together with the capacitor component 24, and another part of the filter component 23 is potted separately in the third accommodating chamber 2121. The present application realizes modularization by making the capacitor component 24, the filter component 23 and the water-cooling plate 22 share a housing 21, while reducing the volume of the inverter brick assembly 2, saving the internal space of the motor controller 10, and because the capacitor component 24 and the filter component 23 are both integrated in the housing 21 by potting, the production difficulty and cost are reduced.

[0031] In a specific embodiment, if Figure 2 As shown, the first housing portion 211 may be a rectangular parallelepiped structure, a second accommodating cavity 2112 is provided inside the first housing portion 211, a first accommodating cavity 2111 is provided on the outer surface of the first housing portion 211 at intervals from the second accommodating cavity 2112, and the second accommodating cavity 2112 may be a groove formed on the side wall of the first housing portion 211. Through the above structure, the water-cooling plate 22 and the capacitor assembly 24 can share a housing 21, reducing the thickness of the housing 21 in the second direction D2, solving the problem of height space limitation in the second direction D2, thereby improving or reducing the impact on the luggage compartment space. Through the above structure, the water-cooling plate 22 can also achieve the heat dissipation function of the capacitor assembly 24 and the filter assembly 23, and improve stability.

[0032] Furthermore, the process of integrating and encapsulating the capacitor component 24 and the filter component 23 in the housing 21 can be to first manufacture the housing 21 for encapsulation, then place the capacitor component 24 and the filter component 23 in the second accommodating cavity 2112 and the third accommodating cavity 2121 of the housing 21, respectively, and then perform encapsulation to form the finished capacitor component 24 and the finished filter component 23, and finally perform offline testing. Through the above-mentioned encapsulation integration method, production efficiency can be improved, the internal space of the motor controller 10 can be saved, the modularization of the inverter brick assembly 2 can be realized, and the problems of complex structure, difficult production and high cost of the filter component 23 can be solved.

[0033] In one embodiment of the present application, the filter component 23 includes a nanocrystalline magnetic ring 231, and the inverter brick assembly 2 also includes a sealing component 25. Along the third direction D3, the third accommodating cavity 2121 is provided with two opposite openings 2122. The nanocrystalline magnetic ring 231 passes through one opening 2122 and is encapsulated in the third accommodating cavity 2121. The sealing component 25 is covered at the other opening 2122 to partially cover and seal the opening 2122. The third direction D3 is perpendicular to both the first direction D1 and the second direction D2.

[0034] Specifically, the filter assembly 23 also includes a ferrite magnetic ring 233. Since the ferrite magnetic ring 233 is composed of silicon steel sheets and has a certain strength, this part of the potting can also use the same epoxy potting glue as the capacitor assembly 24. After integration, it is potted in the second accommodating cavity 2112 with the capacitor assembly 24, which does not affect the performance. However, the nanocrystalline magnetic ring 231 is different. The nanocrystalline structure is a relatively thin and brittle film. After winding and forming, a slight force on the sides of both sides will cause the edge of the film to be damaged. Therefore, the epoxy potting glue with very high hardness and high strength after curing cannot be used like the capacitor assembly 24 and the ferrite magnetic ring 233, and the nanocrystalline magnetic ring 231 needs to be potted separately. In a specific embodiment, the second shell portion 212 can be a rectangular shell that runs through the front and back, and a third accommodating cavity 2121 is provided in the rectangular shell for potting the nanocrystalline magnetic ring 231 separately. In the third accommodating cavity 2121, a relatively soft silicone with good fluidity, low hardness after curing, and good elasticity can be used to pot the nanocrystalline magnetic ring 231, thereby improving or avoiding the problem of sensitive potting stress of the nanocrystalline magnetic ring 231 and poor filtering effect. It should be noted that if the capacitor component 24 is potted with the same silicone as the nanocrystalline magnetic ring 231, due to the large volume of the capacitor component 24, it is easy to have insufficient strength after potting, and the vibration resistance is not enough to cause the problem of falling off. Therefore, according to the characteristics of the capacitor component 24 and the nanocrystalline magnetic ring 231, different potting glues need to be used, so that the third accommodating cavity 2121 is designed to be separated from the second accommodating cavity 2112 and the first accommodating cavity 2111 and set independently.

[0035] In one embodiment of this application, please continue to combine Figure 3 , Figure 3 yes Figure 1 Schematic diagram of the structure of the housing and the filter assembly. The filter assembly 23 also includes an injection molded body 232. Before the nanocrystalline magnetic ring 231 is encapsulated in the third accommodating cavity 2121, the injection molded body 232 is connected and fixed to the side of the nanocrystalline magnetic ring 231 facing the opening 2122, and is used to cooperate with the sealing assembly 25 to achieve the covering and sealing of the opening 2122. The sealing assembly 25 includes a first cover plate 251 and a second cover plate 252. The first cover plate 251 is provided with a notch 253. Along the second direction D2, the notch 253 includes a first sealing port 2531 and a second sealing port 2532 that are interconnected. Specifically, after the injection molded body 232 passes through the third accommodating cavity 2121, the first cover plate 251 covers the opening 2122, so that the injection molded body 232 passes through the second sealing port 2532 and is located in the first sealing port 2531, and the second cover plate 252 is covered in the second sealing port 2532 to achieve the covering and sealing.

[0036] Therefore, the entire sealing process can be summarized as placing the nanocrystalline magnetic ring 231 in the third accommodating cavity 2121, so that the injection molded body 232 is located at one of the openings 2122, and the first cover plate 251 is covered at the opening 2122 along the third direction D3, so that the injection molded body 232 enters the first sealing port 2531 along the second sealing port 2532. At this time, the opening 2122 except for the second sealing port 2532 is sealed by the cooperation of the injection molded body 232 and the first cover plate 251, and then the second cover plate 252 is covered at the second sealing port 2532 to achieve the sealing of the opening 2122 located at the second sealing port 2532.

[0037] In a specific embodiment, the first sealing groove 2533 is provided on the opposite side walls of the first sealing opening 2531, the second sealing groove 2534 is provided on the opposite side walls of the second sealing opening 2532, the third sealing groove 2321 is provided on the opposite side walls of the injection molding body 232, and the fourth sealing groove 2521 is provided on the opposite sides of the second cover plate 252. The first sealing groove 2533 can cooperate with the third sealing groove 2321 to achieve the sealing of the first sealing opening 2531. The second sealing groove 2534 can cooperate with the fourth sealing groove 2521 to achieve the sealing of the second sealing opening 2532. The inner wall of the third accommodating cavity 2121 can also be provided with a sliding groove 2123 to facilitate the installation of the first cover plate 251, and the outer peripheral surface of the first cover plate 251 can cover the opening 2122 along the sliding groove 2123 to achieve sealing. Of course, in other specific embodiments, the opening 2122 of the third accommodating cavity 2121 can also be sealed in other ways.

[0038] Please continue to combine Figure 4 , Figure 4 yes Figure 1Schematic diagram of the structure of the filter component. Further, the filter component 23 also includes a first copper bar 234, a second copper bar 235, a first circuit board 236 and a second circuit board 237. The first copper bar 234 is used for inputting current, the second copper bar 235 is used for outputting current, and the first circuit board 236 and the second circuit board 237 are both used to realize the filtering function and improve stability.

[0039] In a specific embodiment, the filter assembly 23 can be an LCL filter (Longitudinal Conversion Loss). Along the first direction D1, the second copper bar 235, the second circuit board 237, the ferrite magnetic ring 233 and the nanocrystalline magnetic ring 231 are arranged in sequence. The first copper bar 234 extends along the third direction D3 to pass through the nanocrystalline magnetic ring 231, and then extends in the opposite direction of the third direction D3 and connects to the first circuit board 236. When the filter assembly 23 is potted with the capacitor assembly 24, the nanocrystalline magnetic ring 231, the injection molding 232 and a part of the first copper bar 234 of the filter assembly 23 are potted in the third accommodating cavity 2121, and the rest of the filter assembly 23 is potted in the second accommodating cavity 2112 together with the capacitor assembly 24, so as to improve production efficiency and save space and reduce the impact on the filtering effect.

[0040] Furthermore, the first copper busbar 234 is provided with an input port 238, and an output port 239 is provided at the position of the second copper busbar 235 or the second circuit board 237, and the output port 239 is welded to the connecting busbar 241 of the capacitor assembly 24 to realize the electrical connection between the filter assembly 23 and the capacitor assembly 24. The current is input into the filter assembly 23 through the input port 238, and is then output to the capacitor assembly 24 through the output port 239 after being filtered by the filter assembly 23.

[0041] Please continue to combine Figures 5 to 7 , Figure 5 yes Figure 1 The schematic diagram of the overall assembly of the inverter brick assembly. Figure 6 yes Figure 1 The schematic diagram of the structure of the middle inverter brick assembly after overall assembly. Figure 7 yes Figure 6 In one embodiment of the present application, the inverter brick assembly 2 further includes a Hall element 26, a control drive integrated board 27 and a power device 28, such as Figure 5 and Figure 7 As shown, along the second direction D2, the Hall element 26, the control and drive integrated board 27 and the power device 28 are sequentially arranged above the water cooling plate 22.

[0042] Specifically, along the second direction D2, the power device 28 is fixed on the housing 21 and is located above the water-cooled plate 22 to facilitate heat dissipation and cooling. A portion of the control-drive integrated board 27 is connected and fixed to the power device 28, and the other portion is connected and fixed to the housing 21. The Hall element 26 includes a three-phase line Hall 261 and a three-phase line copper bus 262. The three-phase line copper bus 262 is inserted into the three-phase line Hall 261. The three-phase line Hall 261 is fixedly connected to the housing 21 and is located above the control-drive integrated board 27. It should be noted that the power device 28 of the embodiment of the present application can be an IGBT module (Insulated Gate Bipolar Transistor), and can also include other devices, which are not limited here.

[0043] Further, the capacitor terminal 242 of the capacitor assembly 24 exposed in the second accommodating cavity 2112 is connected to the connecting terminal 281 on the power device 28, and the output terminal 282 on the power device 28 is connected to the three-phase copper bus 262. The current can be output through the three-phase copper bus 262 after passing through the filter assembly 23, the capacitor assembly 24 and the power device 28. It should be noted that whether it is the input port 238, the output port 239 or the busbar connection copper bus, the capacitor terminal 242 and the connecting terminal 281, they all include positive and negative ports and positive and negative terminals, wherein the positive pole is connected to the positive pole, and the negative pole is connected to the negative pole. Regarding the circuit connection structure, it will not be repeated here.

[0044] In one embodiment of the present application, Figure 5 and Figure 7 The first accommodating cavity 2111 is provided with two side walls opposite to each other along the first direction D1, and a liquid inlet interface 2113 and a liquid outlet interface 2114 are provided at the bottom of the side walls. Along the second direction D2, at least a portion of the liquid inlet interface 2113 and at least a portion of the liquid outlet interface 2114 are located above the water cooling plate 22, so that the coolant can flow through the surface of the water cooling plate 22, shortening the heat dissipation path and improving the cooling efficiency.

[0045] In a specific embodiment, the water-cooled plate 22 can be arranged on the bottom wall of the first accommodating chamber 2111, that is, the cooling channel 29 is formed by the side wall and the water-cooled plate 22 with the liquid inlet interface 2113 and the liquid outlet interface 2114, so that the coolant can flow directly from the surface of the water-cooled plate 22, thereby improving the smoothness of the coolant flow. In another specific embodiment, the liquid inlet interface 2113 and the liquid outlet interface 2114 can also be completely located below the water-cooled plate 22, that is, the water-cooled plate 22 and the bottom wall of the first accommodating chamber 2111 have a certain distance, but such an arrangement will increase the height of the inverter brick assembly 2 in the second direction D2 and increase the volume. In another specific embodiment, the liquid inlet interface 2113 and the liquid outlet interface 2114 can also be completely located above the water-cooled plate 22, but such an arrangement will affect the smoothness of the coolant flow.

[0046] Furthermore, if Figure 7 As shown, a cooling channel 29 is formed between the power device 28 and the housing 21 , and the cooling channel 29 is connected to the liquid inlet interface 2113 and the liquid outlet interface 2114 .

[0047] In a specific embodiment, the cooling channel 29 is a channel formed between the power device 28 and the water-cooled plate 22 and the inner wall of the first accommodating chamber 2111 in the first accommodating chamber 2111. The coolant flows into the cooling channel 29 from the liquid inlet interface 2113, and after taking away the heat generated by the power device 28, it flows out from the liquid outlet interface 2114 to achieve heat dissipation and cooling performance. The sealing assembly 25 may also include a sealing ring (not shown), which is arranged between the water-cooled plate 22 and the power device 28, which can improve the sealing performance and improve or avoid the problem of coolant leakage.

[0048] Furthermore, combined with Figure 1 As shown, a coolant inlet 11 and a coolant outlet 12 are provided in the controller housing 1 , the liquid inlet interface 2113 is communicated with the coolant inlet 11 , and the liquid outlet interface 2114 is communicated with the coolant outlet 12 .

[0049] In a specific embodiment, in conjunction with reference Figure 6, a liquid inlet channel 213 and a liquid outlet channel 214 connected to the cooling channel 29 are provided in the shell 21, and the liquid inlet channel 213 and the liquid outlet channel 214 are respectively connected to the coolant inlet 11 and the coolant outlet 12, so that the cooling channel 29 is connected to the coolant inlet 11 and the coolant outlet 12. The above structure can realize the continuous flow of coolant, improve the heat dissipation efficiency and performance, and form a cooling circuit that passes through the coolant inlet 11, the liquid inlet interface 2113, the cooling channel 29, the liquid outlet interface 2114 and the coolant outlet 12 in sequence. It should be noted that the liquid inlet channel 213 is provided with a liquid inlet 2131, and the liquid outlet channel 214 is provided with a liquid outlet 2141. The liquid inlet 2131 and the coolant inlet 11, and the liquid outlet 2141 and the coolant outlet 12 are all sealed to improve or avoid coolant leakage.

[0050] Please refer to Figure 8 , Figure 8 The present application also includes a second technical solution, providing an electric drive assembly 100, including the above-mentioned motor controller 10 and a motor housing 20 and a reducer housing 30 arranged in sequence along the first direction D1, the motor housing 20, the reducer housing 30 and the controller housing 1 are integrated by die-casting, which can reduce the volume of the electric drive assembly 100 and reduce the cost.

[0051] Specifically, since the electric drive assembly 100 includes the motor controller 10 described in the above embodiment, it also has the beneficial effects of the above motor controller 10, which will not be described in detail here.

[0052] Furthermore, the controller housing 1 is also provided with a coolant inlet hole 13 and a coolant outlet hole 14 connected to the outside. The coolant inlet hole 13 is connected to the coolant inlet 11, and the coolant outlet hole 14 is respectively connected to the coolant outlet 12 and the heat exchanger on the electric drive assembly 100.

[0053] The inverter brick assembly 2 of the embodiment of the present application can support a variety of application scenarios through modular design, improve assembly and testing efficiency, for example, it can be installed in a three-in-one housing 21 in an inverted manner or in a forward manner. It should be noted that the three-in-one housing 21 here refers to a housing 21 formed by integrating the motor housing 20, the reducer housing 30 and the controller housing 1 with die-casting.

[0054] Furthermore, the electric drive assembly 100 also includes a motor, a reducer (not shown) and a high-voltage wire harness 40. The motor is arranged in the motor housing 20, the reducer is arranged in the reducer housing 30, and the high-voltage wire harness 40 passes through the controller housing 1 and is electrically connected to the inverter brick assembly 2 to realize the DC to AC conversion function.

[0055] Since the motor housing 20, the reducer housing 30 and the controller housing 1 are integrated by die-casting, in order to realize the production line assembly of the electric drive assembly 100, it is necessary to merge the controller assembly line and the test line with the electric drive production line to form a high-voltage wire harness 40, thereby increasing the control requirements of the electric drive production line assembly environment and the production line investment.

[0056] In a specific embodiment, the motor controller 10 further includes a busbar copper bar assembly 3, the controller housing 1 is provided with a through hole 15, the high-voltage wire harness 40 passes through the through hole 15 and is connected to the input copper bar 31 of the busbar copper bar assembly 3, the output copper bar 32 of the busbar copper bar is connected to the input port 238 of the filter assembly 23, and the current passes through the inverter brick assembly 2 to realize the DC to AC function. The electric drive assembly 100 also includes a three-phase line transfer copper bar 50, which is respectively connected to the three-phase line copper bar 262 and the motor, so that the AC power is transmitted to the motor through the three-phase line transfer copper bar 50.

[0057] Furthermore, the motor controller 10 further includes an upper cover 4 for covering the controller housing 1. The controller housing 1 is sealedly connected to the upper cover 4, the three-phase wire transfer copper bar 50, and the high-voltage wire harness 40 to achieve sealing protection of the motor controller 10 from the outside.

[0058] On the other hand, the present application further provides a vehicle, which includes the above-mentioned electric drive assembly 100. Specifically, since the vehicle includes the electric drive assembly 100 described in the above embodiment, it also has the beneficial effects of the above-mentioned electric drive assembly 100, which will not be repeated here.

[0059] It should be noted that the terms "horizontal", "vertical" and the like do not mean that the components are required to be absolutely horizontal or vertical, but can be slightly tilted; the terms "parallel" and "vertical" and the like do not mean that the components are absolutely parallel or vertical, but can form a certain angle deviation. For example, "horizontal" only means that its direction is more horizontal than "vertical", and does not mean that the structure must be completely horizontal, but can be slightly tilted. In addition, the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like indicate the orientation or position relationship based on the orientation or position relationship shown in the drawings, or the orientation or position relationship in which the product of the present application is usually placed when used, which is only for the convenience of describing the embodiments of the present application and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation to the present application.

[0060] It is to be understood that the meaning of "plurality" herein is at least two, such as two, three, etc., unless there is a special limitation. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions. For example, a process, method, system, product or device that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units that are not listed, or may optionally include other steps or units that are inherent to these processes, methods, products or devices. The term "and / or" is merely a description of the association relationship of associated objects, indicating that three relationships may exist. For example, A and / or B may represent: A exists alone, A and B exist at the same time, and B exists alone. In addition, the character " / " herein generally indicates that the associated objects before and after are in an "or" relationship.

[0061] The above description is only an implementation method of the present application, and does not limit the patent scope of the present application. Any equivalent structure or equivalent process transformation made using the contents of the present application specification and drawings, or directly or indirectly used in other related technical fields, are also included in the patent protection scope of the present application.

Claims

1. A motor controller, characterized in that: include: Controller housing (1); An inverter brick assembly (2), the inverter brick assembly (2) comprising a housing (21), a water cooling plate (22), a filter assembly (23) and a capacitor assembly (24), the housing (21) being installed in the controller housing (1), the housing (21) comprising a first housing portion (211) and a second housing portion (212), the second housing portion (212) being connected to the first housing portion (211) along a first direction, the first housing portion (211) being provided with a first accommodating cavity (2111) and a second accommodating cavity (2112), the second housing portion (212) being provided with a third accommodating cavity (2121); Wherein, along the first direction, the second accommodating cavity (2112) and the third accommodating cavity (2121) are arranged at intervals, and along the second direction, the first accommodating cavity (2111) and the second accommodating cavity (2112) are arranged at intervals, the first direction is perpendicular to the second direction, and the second direction and the arrangement direction of the housing (21) and the controller housing (1) are parallel; The water cooling plate (22) is arranged in the first accommodating cavity (2111), a part of the filter component (23) is integrated and sealed together with the capacitor component (24) in the second accommodating cavity (2112), and another part of the filter component (23) is separately sealed in the third accommodating cavity (2121).

2. The motor controller according to claim 1, characterized in that: The filter component (23) comprises a nanocrystalline magnetic ring (231); The inverter brick assembly (2) further comprises a sealing component (25); along the third direction, the third accommodating cavity (2121) is provided with two opposite openings (2122); the nanocrystalline magnetic ring (231) passes through one of the openings (2122) and is encapsulated in the third accommodating cavity (2121); and the sealing component (25) is covered at the other opening (2122); The third direction is perpendicular to both the first direction and the second direction.

3. The motor controller according to claim 2, characterized in that: The filter component (23) further comprises an injection molded body (232), wherein the injection molded body (232) is connected and fixed to a side of the nanocrystalline magnetic ring (231) facing the opening (2122); The sealing assembly (25) comprises a first cover plate (251) and a second cover plate (252), wherein the first cover plate (251) is provided with a notch (253), and along the second direction, the notch (253) comprises a first sealing opening (2531) and a second sealing opening (2532) which are interconnected; wherein, after the injection molded body (232) passes through the third accommodating cavity (2121), the first cover plate (251) covers the opening (2122), so that the injection molded body (232) passes through the second sealing opening (2532) and is located in the first sealing opening (2531), and the second cover plate (252) is covered in the second sealing opening (2532).

4. The motor controller according to any one of claims 1 to 3, characterized in that: The inverter brick assembly (2) further comprises a Hall element (26), a control drive integrated board (27) and a power device (28), and along the second direction, the Hall element (26), the control drive integrated board (27) and the power device (28) are sequentially arranged above the water cooling plate (22).

5. The motor controller according to claim 4, characterized in that: The first accommodating cavity (2111) is provided with two side walls opposite to each other along the first direction, and a liquid inlet interface (2113) and a liquid outlet interface (2114) are provided at the bottom of the side walls. Along the second direction, at least a portion of the liquid inlet interface (2113) and at least a portion of the liquid outlet interface (2114) are both located above the water cooling plate (22).

6. The motor controller according to claim 5, characterized in that: A cooling channel (29) is formed between the power device (28) and the housing (21), and the cooling channel (29) is connected to the liquid inlet interface (2113) and the liquid outlet interface (2114).

7. The motor controller according to claim 5, characterized in that: A cooling liquid inlet (11) and a cooling liquid outlet (12) are provided in the controller housing (1); the liquid inlet interface (2113) is in communication with the cooling liquid inlet (11), and the liquid outlet interface (2114) is in communication with the cooling liquid outlet (12).

8. An electric drive assembly, comprising the motor controller according to any one of claims 1 to 7, characterized in that: The electric drive assembly further comprises a motor housing (20) and a reducer housing (30) arranged in sequence along the first direction, and the motor housing (20), the reducer housing (30) and the controller housing (1) are integrally die-cast.

9. The electric drive assembly according to claim 8, characterized in that: The electric drive assembly also includes a motor, a reducer and a high-voltage wire harness (40); the motor is arranged in the motor housing (20); the reducer is arranged in the reducer housing (30); and the high-voltage wire harness (40) passes through the controller housing (1) and is electrically connected to the inverter brick assembly (2).

10. A vehicle, characterized in that: include: The electric drive assembly according to claim 8 or 9.

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