Controller, electric assembly and vehicle

Abstract

The invention discloses a controller, an electric assembly and a vehicle. The controller comprises a box body and an adapter. The box body comprises a side wall. A first containing cavity and a second containing cavity are defined by the side walls. The adapter is arranged on the inner side of the side wall and comprises a first end and a second end which are opposite to each other. The first end extends into the first containing cavity, and the second end extends into the second containing cavity. And the first end extends into the first accommodating cavity, and the second end extends into the second accommodating cavity, so that the spatial layout of each component in the controller is optimized.

Description

Technical Field

[0001] The present application relates to the field of controller technology, and more specifically, to a controller, an electric assembly and a vehicle. Background Art

[0002] With the development of technology, more and more components are integrated into the controller to achieve more functions. However, the installation space of the controller is limited. In order to arrange more components in the controller in the limited installation space, it is necessary to optimize the spatial layout of each component in the controller. Summary of the invention

[0003] Embodiments of the present application provide a controller, an electric assembly, and a vehicle.

[0004] The controller of the embodiment of the present application includes a box body and an adapter. The box body includes a side wall. The side wall surrounds and forms a first accommodating cavity and a second accommodating cavity. The adapter is arranged on the inner side of the side wall and includes a first end and a second end opposite to each other. The first end extends into the first accommodating cavity, and the second end extends into the second accommodating cavity.

[0005] In some embodiments, the box body further includes a partition wall connected to the side wall; the partition wall is used to separate the first accommodating cavity and the second accommodating cavity; and the adapter is disposed through the partition wall.

[0006] In some embodiments, the side wall includes a first side wall and a second side wall; the first side wall and the second side wall are arranged on both sides of the partition wall; the first side wall and the partition wall are used to form the first accommodating cavity; the second side wall and the partition wall are used to form the second accommodating cavity.

[0007] In some embodiments, the adapter is fixedly connected to the box.

[0008] In some embodiments, the adapter includes an adapter portion and a mounting portion connected to each other, the adapter portion is used for circuit switching; the mounting portion is provided with a through hole, and the through hole is used for fixed connection with the box body.

[0009] In some embodiments, the adapter portion is plate-shaped, and the mounting portion includes a first mounting portion and a second mounting portion; the first mounting portion and the second mounting portion are arranged on two opposite sides of the adapter portion.

[0010] In some embodiments, one side surface of the plate-shaped adapter faces the side wall and is disposed adjacent to the side wall.

[0011] In some embodiments, it also includes a control component and a power supply component; the control component is disposed in the first accommodating cavity; the power supply component is disposed in the second accommodating cavity; the first end of the adapter is used to be electrically connected to the control component; the second end of the adapter is used to be electrically connected to the power supply component.

[0012] In some embodiments, the power supply assembly includes a connector, and the connector is inserted into the box; the second end is used to electrically connect to an end of the connector located in the second accommodating cavity.

[0013] In some embodiments, the control assembly includes a discharge plate, and the first end is used to be electrically connected to the discharge plate.

[0014] In some embodiments, the power supply component includes a filter board; the filter board is electrically connected to the DC circuit; the filter board is also electrically connected to the discharge board of the control component.

[0015] In some embodiments, the first end of the adapter is electrically connected to the control assembly via a wiring harness; and the second end of the adapter is electrically connected to the power supply assembly via a wiring harness.

[0016] In some embodiments, a wire nose is disposed on both the first end and the second end of the adapter, and the wire nose is used to connect to the wire harness.

[0017] In some embodiments, at least two first electrical connection terminals are provided on the first end of the adapter; at least two second electrical connection terminals are provided on the second end of the adapter; the first electrical connection terminals and the second electrical connection terminals are arranged in one-to-one correspondence, and the corresponding first electrical connection terminals are electrically connected to the second electrical connection terminals.

[0018] In some embodiments, at least two of the first electrical connection ends are distributed in a stepped manner so that at least two of the first electrical connection ends are staggered in the direction from the first end to the second end; at least two of the second electrical connection ends are distributed in a stepped manner so that at least two of the second electrical connection ends are staggered in the direction from the first end to the second end.

[0019] In some embodiments, the controller also includes a relay; the box body also includes a partition wall connected to the side wall; the partition wall is used to separate the first accommodating chamber and the second accommodating chamber; the relay is arranged in the first accommodating chamber and / or the second accommodating chamber; the relay includes an access part and a driving part; the access part is used to access a circuit controlled by the relay; the driving part is used to control the connection or disconnection of the access part; the arrangement direction of the access part and the driving part is perpendicular to the surface normal of the partition wall.

[0020] In some embodiments, the controller is formed with a charging circuit, a boost circuit, a current boost circuit and a heating circuit; the charging circuit, the boost circuit, the current boost circuit and the heating circuit are at least partially formed on the capacitor assembly; the charging circuit is used to transfer the DC power supply to the battery connected to the controller; the boost circuit is used to increase the voltage of the DC power supply and then transfer it to the battery connected to the controller; the current boost circuit is used to increase the current of the DC power supply and then transfer it to the battery connected to the controller; the heating circuit is used to heat the electrical system connected to the controller.

[0021] In some embodiments, the capacitor assembly is also used to be electrically connected to a battery outside the controller; the capacitor assembly also includes a power distribution conductive bar, which is electrically connected to the DC power supply and / or the battery, and the power distribution conductive bar is also electrically connected to the power supply assembly of the controller.

[0022] In some embodiments, the control component of the controller further includes a power device module, and the capacitor component is electrically connected to the power device module.

[0023] In some embodiments, the capacitor assembly is connected to the power device module by laser welding.

[0024] In some embodiments, the control component of the controller further includes a DC charging filter; the relay is disposed on the DC charging filter; and the DC charging filter is used to be electrically connected to an external DC power supply of the controller.

[0025] In some embodiments, the controller is formed with a charging circuit and a boost circuit; at least part of the charging circuit and the boost circuit are arranged on the DC charging filter; two relays are arranged on the DC charging filter; and the two relays are respectively connected to the charging circuit and the boost circuit.

[0026] In some embodiments, the control component of the controller includes a three-phase conductive bar assembly; the three-phase conductive bar assembly is used to be electrically connected to the power device module of the control component; the three-phase conductive bar assembly includes a second shell, a U-phase conductive bar, a V-phase conductive bar, a W-phase conductive bar and a first filter magnetic ring; the second shell, the U-phase conductive bar, the V-phase conductive bar, the W-phase conductive bar and the first filter magnetic ring are integrally injection molded.

[0027] In some embodiments, the control component of the controller includes a DC bus filter; the DC bus filter is used to be electrically connected to the capacitor component of the control component; the DC bus filter includes an X capacitor, a Y capacitor and a second filter magnetic ring, and the X capacitor, the Y capacitor and the second filter magnetic ring are all used to filter the circuit connected to the DC bus filter.

[0028] The electric assembly according to the embodiment of the present application includes the above-mentioned controller.

[0029] In some embodiments, the electric assembly also includes a connected motor and a reducer; the housing also includes a partition wall connected to the side wall; the partition wall is used to separate the first accommodating cavity and the second accommodating cavity; the side wall includes a first side wall and a second side wall; the first side wall and the partition wall are used to form the first accommodating cavity; the second side wall and the partition wall are used to form the second accommodating cavity; the partition wall is connected to the motor and the reducer; the first side wall is arranged on the side of the partition wall facing away from the motor; the second side wall is arranged on the side of the partition wall facing the motor, and is located in the space enclosed by the motor and the reducer; the controller also includes a power supply component, and the power supply component is arranged in the second accommodating cavity.

[0030] In some embodiments, the motor includes a first shell and a rotor, the reducer includes a second shell and a reduction mechanism, the rotor is arranged in the first shell, and the reduction mechanism is arranged in the second shell; the first shell, the second shell and the box body are integrally formed.

[0031] The vehicle according to the embodiment of the present application includes the above-mentioned controller or the above-mentioned electric assembly.

[0032] In the embodiment of the present application, the housing of the controller includes a side wall, and the first accommodating cavity and the second accommodating cavity formed by the side wall are spaces for installing electronic devices. The first accommodating cavity and the second accommodating cavity can accommodate different components. There needs to be an electrical connection relationship between different components, and this electrical connection relationship can be either a signal connection or a connection for transmitting electrical energy. The adapter is a device that plays a role of adapter in the electrical connection structure between different components; a component can be electrically connected to the first end of the adapter, and the second end of the adapter is electrically connected to another component, thereby realizing the electrical connection of the two components. The first end of the adapter extends into the first accommodating cavity, and the second end of the adapter extends into the second accommodating cavity, so as to facilitate the electrical connection of the components in the first accommodating cavity with the first end, and facilitate the electrical connection of the components in the second accommodating cavity with the second end, so that the components in the first accommodating cavity can be conveniently electrically connected to the components in the second accommodating cavity through the adapter, which makes the connection circuit between the components in the first accommodating cavity and the second accommodating cavity more regular. Therefore, the embodiment of the present application optimizes the spatial layout of the components in the controller.

[0033] Additional aspects and advantages of the present application will be given in part in the description below, and in part will become apparent from the description below, or will be learned through the practice of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] The above and / or additional aspects and advantages of the present application will become apparent and easily understood from the description of the embodiments in conjunction with the following drawings, in which:

[0035] Figure 1 is a three-dimensional exploded schematic diagram of a controller of certain embodiments of the present application;

[0036] Figure 2 yes Figure 1 A first-perspective stereoscopic diagram of an adapter of the controller shown;

[0037] Figure 3 yes Figure 1 A second perspective perspective diagram of the adapter of the controller shown;

[0038] Figure 4 yes Figure 1 The assembly diagram of the controller shown;

[0039] Figure 5 yes Figure 1 The controller shown is an assembly diagram with the lower cover removed;

[0040] Figure 6 yes Figure 5 A magnified view of part A;

[0041] Figure 7 yes Figure 1The schematic diagram of the assembly of the controller housing, adapter and discharge board shown;

[0042] Figure 8 yes Figure 7 A magnified view of part B;

[0043] Fig. 9 yes Figure 1 A first-view assembly diagram of a capacitor assembly of the controller shown;

[0044] Fig.10 yes Figure 1 A schematic diagram of the assembly of the capacitor component of the controller from a second perspective is shown;

[0045] Fig.11 yes Figure 1 The assembly diagram of the capacitor component and the power device module of the controller shown;

[0046] Fig.12 yes Figure 1 An exploded schematic diagram of the controller shown having laser welded overlapping conductive bars and high temperature resistant insulating partitions;

[0047] Fig.13 yes Figure 1 The assembly diagram of the capacitor component and relay of the controller shown;

[0048] Fig.14 yes Figure 1 The schematic diagram of the assembly of the relay of the controller and the capacitor assembly with part of the first housing removed;

[0049] Fig.15 yes Figure 1 The assembly diagram of the capacitor component and the adapter board of the controller shown;

[0050] Fig.16 yes Figure 1 The assembly diagram of the capacitor component, adapter board and DC charging filter of the controller shown;

[0051] Fig.17 yes Figure 1 An exploded schematic diagram of the DC charging filter and relay of the controller shown;

[0052] Fig.18 yes Figure 1 The assembly diagram of the DC charging filter and relay of the controller shown;

[0053] Fig.19 yes Figure 1 An exploded schematic diagram of the DC charging filter and adapter board of the controller shown;

[0054] Fig. 20 yes Figure 1An exploded schematic diagram of a DC charging filter of the controller shown;

[0055] Fig.21 yes Figure 1 The schematic diagram of the assembly of the three-phase conductive bar assembly of the controller shown;

[0056] Fig. 22 yes Figure 1 A first-view assembly diagram of a DC bus filter of the controller shown;

[0057] Fig.23 yes Figure 1 A second perspective assembly diagram of a DC bus filter of the controller shown;

[0058] Fig.24 yes Figure 1 The topology diagram of the DC bus filter, DC charging filter and capacitor components of the controller shown;

[0059] Fig.25 yes Figure 1 The controller shown is an assembly diagram with the upper cover removed;

[0060] Fig.26 yes Figure 1 The controller shown is an assembly diagram after removing the upper cover, control components and discharge board;

[0061] Fig. 27 yes Fig.26 A cross-sectional schematic diagram of the controller in the CC direction shown;

[0062] Fig.28 yes Fig.26 A cross-sectional schematic diagram of the controller in the DD direction shown;

[0063] Fig.29 yes Fig.26 A schematic cross-sectional view of the controller in the EE direction is shown;

[0064] Fig.30 yes Fig.26 A cross-sectional schematic diagram of the controller in the FF direction shown;

[0065] Fig.31 yes Figure 1 The schematic diagram of the assembly of the controller housing and capacitor assembly shown;

[0066] Fig.32 yes Figure 1 The schematic diagram of the controller box shown is after the cover is removed;

[0067] Fig.33 yes Figure 1The schematic diagram of the assembly of the controller housing with the first water distribution plate and the second water distribution plate after the cover plate is removed is shown;

[0068] Fig.34 yes Figure 1 A schematic diagram of a housing of the controller shown;

[0069] Fig.35 yes Figure 1 The controller shown is an assembly diagram after removing the lower cover and power supply assembly;

[0070] Fig.36 is a first-view assembly diagram of an electric assembly according to certain embodiments of the present application;

[0071] Fig.37 yes Fig.36 A second perspective assembly diagram of the electric assembly shown. DETAILED DESCRIPTION

[0072] 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. In the following description, many specific details are set forth to facilitate a full understanding of the present application. However, the present application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar improvements without violating the connotation of the present application, so the present application is not limited by the specific implementation methods disclosed below.

[0073] In the description of the present application, it should be understood that the terms "center", "length", "up", "down", "front", "back", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, and do 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 should not be understood as a limitation on the present application.

[0074] In addition, 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 the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In the description of this application, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0075] In this application, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected" and the like 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 or an electrical connection; 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, unless otherwise clearly defined. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0076] In the present application, unless otherwise clearly specified and limited, a first feature being “above” or “below” a second feature may mean that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. Moreover, a first feature being “above”, “above”, and “above” a second feature may mean that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is higher in level than the second feature. A first feature being “below”, “below”, and “below” a second feature may mean that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is lower in level than the second feature.

[0077] Please refer to Figure 1 , Figure 2 , Figure 3 and Fig. 27 The controller 1000 of the embodiment of the present application includes a housing 10 and an adapter 20. The housing 10 includes a side wall 11. The side wall 11 surrounds and forms a first accommodating cavity 14 and a second accommodating cavity 15. The adapter 20 is arranged on the inner side of the side wall 11 and includes a first end 211 and a second end 213 opposite to each other. The first end 211 extends into the first accommodating cavity 14, and the second end 213 extends into the second accommodating cavity 15.

[0078] The controller 1000 may be a drive motor controller, a power distribution unit (PDU) with a battery management system (BMS), a vehicle control unit (Vehicle Control Unit), or a gearbox computer. The housing 10 is a housing for the controller 1000 to accommodate various components. For ease of description, the following description uses a drive motor controller as an example, and the drive motor controller is a drive motor controller of a vehicle, but this does not mean that the controller 1000 provided in this application can only be a drive motor controller of a vehicle.

[0079] In one example, the side wall 11 of the box body 10 may be in the shape of an annulus, in which case the side wall 11 does not close the first accommodating cavity 14 and the second accommodating cavity 15, but only encloses one side of the first accommodating cavity 14 and the second accommodating cavity 15; in another example, the side wall 11 may have four side surfaces that are opposite to each other in pairs, and a bottom surface that is connected to the four side surfaces, thereby closing one of the first accommodating cavity 14 or the second accommodating cavity 15, and leaving the one of the two away from the bottom surface open; in yet another example, the side wall 11 may have four side surfaces that are opposite to each other in pairs, and two bottom surfaces that are respectively connected to the four side surfaces, so that the side wall 11 can close the first accommodating cavity 14 and the second accommodating cavity 15 alone, but in order to facilitate the installation of components in the first accommodating cavity 14 and the second accommodating cavity 15, an installation opening 17 may be opened on a bottom wall to facilitate the installation of components.

[0080] The adapter 20 is arranged on the inner side of the side wall 11, which is equivalent to the adapter 20 being arranged on the side of the side wall 11 facing the first accommodating cavity 14 and the second accommodating cavity 15. The adapter 20 can be directly arranged in the first accommodating cavity 14 and / or the second accommodating cavity 15, but a separate accommodating space can also be opened for the adapter 20 for installation. The adapter 20 can be directly fixedly connected to the side wall 11 to fix the adapter 20; the adapter 20 can also be fixedly connected to other components in the first accommodating cavity 14 and the second accommodating cavity 15 to fix the adapter 20; the adapter 20 can also be fixedly connected to the upper cover 112 or the lower cover 111, so as to complete the fixed installation of the adapter 20; the adapter 20 can also be fixedly connected to the partition wall 16. The fixed connection method of the adapter 20 and the side wall 11, the upper cover 112, the lower cover 111 or the partition wall 16 can be, but not limited to, bonding, welding, screwing or buckling.

[0081] The adapter 20 is a component used for circuit switching. The box 10 is installed with components that need to be electrically connected to each other. However, when the relative position relationship between the two components is not conducive to the wiring harness 500 or the conductive bar to directly connect the two components, the adapter 20 can be used. The two components can be electrically connected to the first end 211 and the second end 213 of the adapter 20 respectively, so as to complete the mutual electrical connection. The adapter 20 plays the role of a conductor in this electrical connection relationship. Please refer to Figure 6 and Figure 8 In one example, the component is connected to the first end 211 of the adapter 20 through a wiring harness 500, and the component is also connected to the second end 213 of the adapter 20 through a wiring harness 500; however, in other examples, the components and the two ends of the adapter 20 can be connected through a conductive bar or directly.

[0082] The first end 211 of the adapter 20 extends into the first accommodating cavity 14, and the first end 211 may enter the first accommodating cavity 14. The second end 213 of the adapter 20 extends into the second accommodating cavity 15, and the second end 213 may enter the second accommodating cavity 15. In this way, the components in the first accommodating cavity 14 can be easily electrically connected to the first end 211, and the components in the second accommodating cavity 15 can be easily electrically connected to the second end 213.

[0083] In the controller 1000 of the embodiment of the present application, the first end 211 of the adapter 20 extends into the first accommodating cavity 14, so that the components in the first accommodating cavity 14 can be conveniently electrically connected to the first end 211, and the second end 213 of the adapter 20 extends into the second accommodating cavity 15, so that the components in the second accommodating cavity 15 can be conveniently electrically connected to the second end 213, so that the components in the first accommodating cavity 14 and the components in the second accommodating cavity 15 can be conveniently electrically connected, so that the connection circuit between the components in the first accommodating cavity 14 and the components in the second accommodating cavity 15 can be more regular. In summary, the embodiment of the present application optimizes the spatial layout of the components in the controller 1000.

[0084] Please refer to Figure 1 , Figure 2 , Figure 4 , Figure 5 and Fig. 27 In some embodiments, the box body 10 further includes a partition wall 16 connected to the side wall 11 . The partition wall 16 is used to separate the first accommodating chamber 14 from the second accommodating chamber 15 . The adapter 20 is disposed through the partition wall 16 .

[0085] exist Figure 1 In the embodiment shown, the first side wall 12 and the second side wall 13 are respectively in the shape of a cylinder wall. In such an embodiment, the surface of the partition wall 16 can be perpendicular or parallel to the generatrix of the first side wall 12 or the second side wall 13. Figure 4In the embodiment shown, it can be seen that the surface of the partition wall 16 is perpendicular to the generatrix of the first side wall 12 or the second side wall 13, so that the first accommodation chamber 14 and the second accommodation chamber 15 are separated into two accommodation chambers arranged along the generatrix direction of the first side wall 12 or the second side wall 13; and in the embodiment where the surface of the partition wall 16 is parallel to the generatrix of the first side wall 12 or the second side wall 13, the partition wall 16 can also separate the first accommodation chamber 14 and the second accommodation chamber 15 into two chambers. In the embodiment where the first side wall 12 and the second side wall 13 are not in the shape of a cylindrical wall, the first partition wall 16 can separate the first accommodation chamber 14 and the second accommodation chamber 15 into two relatively independent chambers in various forms, but relative independence should not be understood as complete isolation. In some embodiments, the first accommodation chamber 14 and the second accommodation chamber 15 can be completely isolated, but in other embodiments, the partition wall 16 can have a connecting structure such as a through hole to connect the first accommodation chamber 14 and the second accommodation chamber 15.

[0086] The partition wall 16 can only play a role of separation, that is, it has no connection relationship with the components in the first accommodating cavity 14 and the second accommodating cavity 15, so that the partition wall 16 can play an isolation role. For example, when the partition wall 16 is made of a conductive material, it can prevent the components in the first accommodating cavity 14 from causing electromagnetic interference to the components in the second accommodating cavity 15, that is, it plays a role of electromagnetic shielding; when the partition wall 16 is made of an insulating material, it can prevent the components in the first accommodating cavity 14 and the second accommodating cavity 15 from transferring heat to each other, thereby playing a role of thermal insulation. The partition wall 16 can also play a bearing role, that is, the components in the first accommodating cavity 14 and the second accommodating cavity 15 are at least partially connected to the partition wall 16, so that the partition wall 16 can fix these components. Please refer to Fig.25 , which can be seen in Fig.25 In the illustrated embodiment, components such as the DC charging filter 80 , the DC bus filter 60 and the capacitor assembly 40 are all fixedly connected to the partition wall 16 .

[0087] Since the partition wall 16 separates the first accommodating chamber 14 and the second accommodating chamber 15, the adapter 20 is inserted through the partition wall 16 so that the first end 211 of the adapter 20 can enter the first accommodating chamber 14, and the second end 213 of the adapter 20 can enter the second accommodating chamber 15, so that the components in the first accommodating chamber 14 can be more easily electrically connected to the first end 211, and the components in the second accommodating chamber 15 can be more easily electrically connected to the second end 213. In addition, due to the setting of the partition wall 16, the components in the first accommodating chamber 14 and the second accommodating chamber 15 are not easy to interfere with each other, which improves the stability of the operation of the controller 1000. In summary, the setting of the partition wall 16 and the insertion of the adapter 20 through the partition wall 16 further optimize the spatial layout of the components in the controller 1000.

[0088] Please refer to Figure 1 , Figure 6 , Figure 7 and Fig. 27 In some embodiments, the side wall 11 includes a first side wall 12 and a second side wall 13. The first side wall 12 and the second side wall 13 are disposed on both sides of the partition wall 16. The first side wall 12 and the partition wall 16 are used to form a first accommodating cavity 14. The second side wall 13 and the partition wall 16 are used to form a second accommodating cavity 15.

[0089] This is equivalent to the partition wall 16 dividing the side wall 11 into two parts, namely the first side wall 12 and the second side wall 13. The first side wall 12 and the second side wall 13 can be set to different shapes, thereby optimizing the overall shape of the box body 10. In an example, please refer to Fig.37 , the controller 1000 can be a driving motor controller and is installed on the motor 3000 and the reducer 2000. In this case, the second side wall 13 can be set to a "convex" shape to adapt to the space between the motor 3000 and the reducer 2000, so that the special-shaped space can be utilized, thereby optimizing the shape of the box 10 and improving the space utilization of the electric assembly 10000. In this embodiment, the partition wall 16 can also be connected to the outside world to play the role of carrying the entire controller 1000.

[0090] Please refer to Figure 1 , Figure 2 , Figure 3 , Figure 5 , Figure 6 , Figure 7 , Figure 8 , Fig.25 , Fig.26 and Fig. 27 In some embodiments, the adapter 20 is fixedly connected to the box body 10.

[0091] When the material of the surface of the adapter 20 is at least partially metal, the adapter 20 can be connected to the case 10 by welding. The adapter 20 can also be bonded to the case 10. When the material of the inner side of the case 10 is at least partially plastic, and the material of the surface of the adapter 20 is at least partially plastic, the case 10 and the adapter 20 can be welded. The case 10 and the adapter 20 can also be connected by bolts. In one embodiment, threaded holes can be opened on the side wall 11, and bolts can also be provided. The bolts pass through the adapter 20 and cooperate with the threaded holes, so that the adapter 20 can be fixed to the side wall 11. Since the case 10 is the carrier that carries the entire controller 1000, making the adapter 20 directly fixedly connected to the case 10 can provide a more stable fixation for the adapter 20 and improve the stability of the adapter 20.

[0092] Please refer to Figures 1 to 3 , Figures 5 to 8 and Figure 25 to Figure 27 In some embodiments, the adapter 20 includes a connecting portion 21 and a mounting portion 26 connected to each other, wherein the connecting portion 21 is used for circuit switching. The mounting portion 26 is provided with a through hole, which is used for fixed connection with the box body 10.

[0093] The adapter 21 is the part of the adapter 20 that is actually used for circuit switching, that is, the first end 211 and the second end 213 are actually arranged on the adapter 21, or the first end 211 and the second end 213 are considered to be the two ends of the adapter 21. The adapter 21 is connected to the mounting portion 26, so only by fixing the mounting portion 26, the adapter 21 can be fixed, that is, it is equivalent to fixing the adapter 20. In one example, the through hole on the mounting portion 26 can be used for rivets to pass through, and the box body 10 can be provided with a hole that matches the rivet. After the rivet passes through the through hole, it matches with the hole on the box body 10, thereby fixing the mounting portion 26 to the box body 10. In another example, the through hole can be opened for bolts to pass through, and the bolts pass through the through hole and match with the corresponding threaded holes on the box body 10, thereby fixing the mounting portion 26.

[0094] The adapter part 21 and the mounting part 26 respectively perform the adapter function and the mounting function, which can avoid mutual influence between the adapter part 21 and the mounting part 26. For example, it can avoid the adapter part 21 being damaged by the installation workpiece during installation, thereby ensuring the complete function of the adapter 20.

[0095] Please refer to Figures 1 to 3 , Figures 5 to 8 and Figure 25 to Figure 27 In some embodiments, the adapter 21 is plate-shaped, and the mounting portion 26 includes a first mounting portion 261 and a second mounting portion 262. The first mounting portion 261 and the second mounting portion 262 are disposed on two opposite sides of the adapter 21.

[0096] The adapter 21 is plate-shaped, and the two opposite sides of the adapter 21 are two places on the adapter 21 that are far apart. The first mounting portion 261 and the second mounting portion 262 are arranged on two opposite sides of the adapter 21, so that the first mounting portion 261 and the second mounting portion 262 can also be far apart. In this way, the adapter 20 and the box body 10 (or other structure for fixing the adapter 20) have two fixed positions that are far apart. When the distance between the fixed positions is far, it is helpful to overcome the rotational torque applied to the adapter 20 by the outside world, thereby improving the stability of the installation of the adapter 20.

[0097] Please refer to Figures 1 to 3 , Figures 5 to 8 and Figure 25 to Figure 27 In some embodiments, the side wall 11 surrounds the installation opening 17 that forms the first accommodating cavity 14 . The through hole is disposed toward the installation opening 17 .

[0098] exist Fig.25As shown in the figure, the first side wall 12 is formed with an installation opening 17, and the installation opening 17 makes the first accommodating cavity 14 open. The installation opening 17 can be used for components such as the control assembly 300 and the discharge plate 31 to be installed in the first accommodating cavity 14. The through hole is arranged toward the installation opening 17, so that when the installation opening 17 is open, the through hole can also be opened toward the installation opening 17, so that it is convenient for structures such as bolts or rivets to pass through the through hole to fix the adapter 20. Therefore, the through hole is arranged toward the installation opening 17 to facilitate the installation of the adapter 20. In addition, the installation opening 17 can also be formed around the second side wall 13.

[0099] Please refer to Figures 1 to 3 , Figures 5 to 8 and Figure 25 to Figure 27 In some embodiments, one side surface of the plate-shaped adapter 20 faces the side wall 11 and is disposed adjacent to the side wall 11 .

[0100] The side of the adapter 20 faces the side wall 11 and is arranged adjacent to the side wall 11, so that the adapter 20 can be as close to the side wall as possible, thereby reducing the space occupied by the first accommodating cavity 14 and the second accommodating cavity 15, and further optimizing the spatial layout of various components in the controller 1000.

[0101] Please refer to Figure 1 , Figure 5 , Figure 7 , Figure 8 , Fig.25 , Fig.26 and Fig. 27 In some embodiments, the controller 1000 further includes a control component 300 and a power component 400. The control component 300 is disposed in the first accommodating chamber 14. The power component 400 is disposed in the second accommodating chamber 15. The first end 211 of the adapter 20 is used to be electrically connected to the control component 300. The second end 213 of the adapter 20 is used to be electrically connected to the power component 400.

[0102] The control component 300 may be a control component 300 for driving a motor 3000, such as Figure 1 As shown, the control assembly 300 may include a Hall assembly 33, a control board shielding plate 34, a control board 35, a driving board 38, a capacitor assembly 40, a three-phase conductive bar assembly 50, a DC bus filter 60, a power device module 70, a DC charging filter 80 and a switching board 311. The DC bus filter 60 is used to connect the DC bus. Specifically, Figure 1 In the illustrated embodiment, the DC bus is first connected to the three-core cable nose 310 , and the three-core cable nose 310 is then connected to the DC bus filter 60 , thereby connecting the DC bus to the control component 300 .

[0103] The capacitor assembly 40 is also referred to as a bus capacitor in some practical applications. The original function of the capacitor assembly 40 is to further filter the DC power connected to the DC bus filter 60 to ensure the stability of the DC power. In addition, the other end of the capacitor assembly 40 is connected to the power device module 70. Due to the working principle of the power device module 70, the power device module 70 itself is a high-intensity interference source. Therefore, the capacitor assembly 40 can also prevent the power device module 70 from interfering with the circuit in the DC bus. However, the function of the capacitor assembly 40 of the present application is not limited to the above-mentioned original function. Please refer to the following for details.

[0104] The power device module 70 is a module that converts the direct current from the DC bus into alternating current that can be used to drive the motor 3000. The direct current connected to the three-core wire nose 310 is first filtered by the capacitor component 40 and then enters the power device module 70. The power device module 70 inverts the direct current into alternating current. The power device module 70 is equivalent to a switch module, and the drive board 38 is a control circuit for driving the switch in the power device module 70 to turn on or off. Also due to the rapid switching of the power device in the power device module 70, the power device module 70 generates strong electromagnetic interference, so a control board shielding plate 34 is set to isolate the power device module 70 from the control board 35 to prevent the control board 35 from being subjected to excessively strong electromagnetic interference. The power device in the power device module 70 can be a silicon carbide power device (SiC) or an insulated gate bipolar transistor (IGBT).

[0105] The control board 35 is the main control module of the control module. The control board 35 can receive the speed signal of the speed sensor of the motor 3000, thereby regulating the frequency of the alternating current generated by the drive board 38, and completing the closed-loop control of the motor 3000. The control board 35 can also receive the voltage and current signals from the adapter board 311, so as to control the current in the control component 300. For example, when it is found that the current of a certain circuit is too large, the circuit can be disconnected through a contactor or other structure. The control board 35 can also communicate with the vehicle control unit (VCU) to obtain the driver's accelerator pedal opening information, brake pedal opening information and the instructions input by the driver in the vehicle computer, so as to control the motor 3000 to meet the driver's operating intention. The adapter board 311 has the function of connecting some components to the control board 35. For example, as can be seen below, the relay 600 and the sampling conductive bar 42 can be electrically connected to the adapter board 311, and the adapter board 311 is electrically connected to the control board 35. However, in some embodiments, there is no obvious difference between the adapter board 311 and the control board 35 , and both can assume the control function. Therefore, it can also be considered that the adapter board 311 and the control board 35 are both part of the control system of the controller 1000 .

[0106] The three-phase conductive bar assembly 50 is electrically connected to the power device module 70. The three-phase AC power generated by the power device module 70 is input into the three-phase conductive bar assembly 50. The three-phase conductive bar assembly 50 then outputs the three-phase power to the controller 1000, thereby outputting the three-phase power to the motor 3000 to operate the motor 3000.

[0107] The Hall device is a device that detects the current intensity through the Hall sensor. The Hall device is usually arranged between the three-phase conductive bar assembly 50 and the power device module 70, or arranged after the three-phase conductive bar assembly 50, so as to detect the three-phase electricity flowing through the three-phase conductive bar assembly 50. The Hall device can detect the current intensity of each phase in the three-phase electricity, so it can be used to obtain information such as the phase and frequency of each phase of the three-phase electricity, and the information can be transmitted to the control board 35, and the control board 35 can adjust the control of the motor 3000 according to the information.

[0108] The DC charging filter 80 is a filter connected to an external DC power source. Figure 1In the illustrated embodiment, the DC charging socket 85 is connected to an external DC power source, and the DC charging socket 85 is further electrically connected to the DC charging filter 80, thereby connecting the external DC power source to the controller 1000. The DC charging socket 85 can be electrically connected to the charging socket of the vehicle through the wiring harness 500, and the charging socket can be plugged into a charging gun outside the vehicle. The charging gun draws power through the charging pile, thereby inputting DC power into the controller 1000. The DC charging filter 80 is electrically connected to the capacitor assembly 40, and the capacitor assembly 40 can transmit the DC power input by the DC charging filter 80 to the DC bus filter 60, and the DC bus filter 60 can transmit the current to the battery pack of the vehicle through the DC bus to complete the charging of the battery. Therefore, the capacitor assembly 40 in the embodiment of the present application can also have at least part of the function of a power distribution unit (PDU). Please refer to Fig. 20 The DC charging filter 80 may also be provided with a Y capacitor circuit board 81, and at least one Y capacitor may be provided on the Y capacitor circuit board 81, so as to filter the current carried by the DC charging filter 80. Please refer to Fig.17 In some embodiments, a plurality of conductive bars are provided on the DC charging filter 80 (for specific functions, refer to the following), and the conductive bars can be fixed and electrically connected to the relay provided on the DC charging filter 80 by means of locking bolts 82.

[0109] For a circuit diagram of an implementation method of directly using the current input by the DC charging filter 80 to charge the battery, please refer to Fig.24 :Please refer to Fig.18 and Fig.24 It can be seen that the current flows from the DC charging line positive electrode interface 801, flows along the conductive row to the DC charging positive electrode input interface 809, and the control board 35 (or adapter board 311) controls Fig.18 The relay 600 on the left side is turned on, and the current flows from the second DC positive charging output interface 808 to the transfer conductive bar interface 807, and then flows into the capacitor component 40 through the second DC positive charging transfer terminal 404, and then flows out of the capacitor component through the first DC positive charging transfer terminal 403. Please refer to Fig.18 , Fig.24 and Fig. 22 , the current flows from the first DC charging positive electrode adapter terminal 403 into the DC bus positive electrode conductive bar 66 to input the current to the positive electrode of the battery, and the negative electrode of the battery returns to the controller 1000 through the DC bus negative electrode conductive bar 64, and the DC bus negative electrode conductive bar 64 is then connected to the DC charging line negative electrode interface 802 through the DC charging negative electrode input conductive bar 39 to form a direct charging closed loop circuit. All conductive bars in this application can be copper bars, aluminum bars or other conductive bars made of conductive materials. The conductive bars can play a conductive role and can realize electrical connection between various components.

[0110] The power supply assembly 400 is the in-vehicle power distribution assembly of the vehicle. The power supply assembly 400 can draw power from the battery and distribute it to the vehicle's electrical appliances, such as the vehicle's headlights, air conditioners, or heaters. Since some of the in-vehicle electrical appliances use AC power, the power supply assembly 400 can also include power devices, such as an IGBT module 430, to invert the battery's DC power into AC power. In one example, the power supply assembly 400 can be directly electrically connected to the battery. Figure 1 In the illustrated embodiment, the power supply assembly 400 may be electrically connected to the battery via the power distribution conductive bar 43 of the capacitor assembly 40 , thereby drawing power from the battery.

[0111] In summary, the power supply assembly 400 and the control assembly 300 are two components with complex structures and relatively independent functions, so the two are respectively arranged in the second accommodating cavity 15 and the first accommodating cavity 14, so that the installation environments of the two are relatively independent, which is convenient for assembling the controller 1000. In addition, when the partition wall 16 is provided, the power devices of the power supply assembly 400 and the control assembly 300 can be prevented from interfering with each other, thereby improving the stability of the operation of the controller 1000.

[0112] Please refer to Figure 5 and Figure 6 In some embodiments, the power supply assembly 400 includes a connector 410, and the connector 410 is disposed through the box body 10. The second end 213 is used to be electrically connected to one end of the connector 410 located in the second accommodating cavity 15.

[0113] The connector 410 is a device that can be plugged with other plugs or sockets to achieve electrical connection. In some embodiments, the connector 410 can be a four-core connector 410. The connector 410 is inserted into the box 10, which means that one end of the connector 410 should be exposed outside the box 10, and the other end is inside the box 10. The end of the connector 410 exposed outside the box 10 can be electrically connected to an external electrical connection device; the end of the connector 410 inside the box 10 can be electrically connected to a device inside the box 10, so the connector 410 provides an electrical connection path between the device inside the box 10 and the device outside the box 10. Since the essence of the connector 410 is to play an electrical connection role, the body of the connector 410 does not need to actually pass through the box 10 in some embodiments, but only needs to open a through hole on the box 10 for one end of the connector 410 to be exposed outside the box 10, and the connector 410 can be considered to be inserted into the box 10. The second end 213 of the adapter 20 is electrically connected to the connector 410, so that the device connected to the first end 211 of the adapter 20 can be electrically connected to the outside through the connector 410. The connector 410 is disposed through the box body 10. In one example, the connector 410 is disposed through the second side wall 13. In another example, the connector 410 is disposed through the partition wall 16.

[0114] Due to the setting of the connector 410, the adapter 20 can be connected to the outside world through the connector 410, so that the components in the controller 1000 that need to be electrically connected to the outside world can be more conveniently electrically connected to the outside world, thereby further optimizing the spatial layout of the components in the controller 1000.

[0115] Please refer to Figure 5 , Figure 6 , Figure 7 and Figure 8 In some embodiments, the control component 300 includes a discharge plate 31 , and the first end 211 is used to be electrically connected to the discharge plate 31 .

[0116] The discharge plate 31 is one of the devices that needs to be connected to the outside world. The discharge plate 31 can take power from the power supply component 400, or directly take power from the power distribution conductive bar 43 of the capacitor component 40, and then transmit it to the second end 213 of the adapter 20 through the first end 211 of the adapter 20, and finally flow to the outside world through the connector 410 to achieve external discharge. A fuse can be set on the discharge plate 31 to provide overload protection for the circuit that discharges to the outside. A current sensor and / or a voltage sensor can also be set on the discharge plate 31 to detect the external discharge situation and avoid excessive discharge. When the discharge plate 31 directly draws power from the power supply assembly 400, the power supply assembly 400 can invert the DC power of the battery into AC power and then supply it to the discharge plate 31. The power supply assembly 400 can also reduce or increase the voltage to meet the needs of external electrical equipment. For example, many electrical appliances require 220V, 50Hz AC power. The power supply assembly 400 can invert the DC power provided by the battery into AC power that meets this condition and then supply it to the discharge plate 31. The discharge plate 31 transmits it to the outside world through the connector 410. In some other embodiments, the discharge plate 31 can also provide DC power to the outside.

[0117] The discharge board 31 can be powered directly from the battery, or powered through the power distribution conductive bar 43 of the capacitor assembly 40, or powered through the DC bus positive conductive bar 66 and the DC bus negative conductive bar 64 of the DC bus filter 60. The discharge board 31 can itself have the function of inverting DC power into AC power, thereby meeting the voltage requirements of external devices.

[0118] In some embodiments, the discharge plate 31 can also transmit the external power back to the controller 1000. The external power transmits the current to the discharge plate 31 through the adapter 20 via the connector 410. The discharge plate 31 can transmit the current to other components in the power supply component 400 or the control component 300. In one example, the discharge plate 31 can transmit the current to the capacitor component 40, and the capacitor component 40 transmits the current to the battery through the DC bus filter 60 to complete the charging of the battery; in another example, the discharge plate 31 can directly transmit the power to the DC bus filter 60 to charge the battery. At this time, the discharge plate 31 can also have a rectification function, so that the external AC power can be rectified into DC power to charge the battery.

[0119] The discharge board 31 is electrically connected to the plug-in connector via the adapter 20 , which facilitates the electrical connection between the discharge board 31 and the outside world and optimizes the spatial layout of the components in the controller 1000 .

[0120] Please refer to Figures 5 to 8 In some embodiments, the power supply assembly 400 includes a filter board 420. The filter board 420 is electrically connected to the DC circuit. The filter board 420 is also electrically connected to the discharge board 31 of the control assembly 300.

[0121] The filter board 420 is a device that can play a filtering effect. For example, the filter board 420 may include components with filtering functions such as X capacitors 61, Y capacitors 62 and / or filter magnetic rings. The DC circuit refers to the DC circuit in the controller 1000, such as the DC circuit in the capacitor assembly 40, the DC bus filter 60 and the DC charging filter 80. The filter board 420 is electrically connected to the DC circuit and to the discharge board 31, so that before the current in the DC circuit enters the discharge board 31, it can pass through the filter board 420 first, and the filter board 420 filters the current before transmitting it to the discharge board 31, so that the current discharged by the discharge board 31 is more stable.

[0122] Please refer to Figures 5 to 8 In some embodiments, the first end 211 of the adapter 20 is electrically connected to the control assembly 300 through the wire harness 500. The second end 213 of the adapter 20 is electrically connected to the power assembly 400 through the wire harness 500. In other embodiments, the first end 211 of the adapter 20 can be electrically connected to the control assembly 300 through a conductive bar, and the second end 213 of the adapter 20 can be electrically connected to the power assembly 400 through a conductive bar. However, since the wire harness 500 is flexible and bendable, it is convenient to arrange it in the compact controller 1000. Therefore, using the wire harness 500 to connect the two ends of the adapter 20 can more conveniently adapt to the compact space layout in the controller 1000.

[0123] Please refer to Figure 2 , Figure 3 and Figures 5 to 8 In some embodiments, the first end 211 and the second end 213 of the adapter 20 are both provided with a wire nose 27, and the wire nose 27 is used to connect with the wire harness 500. The provision of the wire nose 27 can ensure the stability of the connection of the wire harness 500, reduce the contact resistance, and improve the electrical connection effect.

[0124] Please refer to Figure 2 and Figure 3 In some embodiments, at least two first electrical connection terminals 212 are provided on the first end 211 of the adapter 20. At least two second electrical connection terminals 214 are provided on the second end 213 of the adapter 20. The first electrical connection terminals 212 and the second electrical connection terminals 214 are provided in a one-to-one correspondence, and the corresponding first electrical connection terminals 212 are electrically connected to the second electrical connection terminals 214.

[0125] The first electrical connection terminal 212 and the second electrical connection terminal 214 are arranged in a one-to-one correspondence, so that the correspondence between the electrical connection terminals on the adapter 20 is simpler, which can avoid incorrect connection when the adapter 20 is connected to the circuit, and help to improve the assembly efficiency and yield rate of the controller 1000.

[0126] Please refer to Figure 2 and Figure 3 In some embodiments, at least two first electrical connection ends 212 are distributed in a stepped manner, so that at least two first electrical connection ends 212 are staggered in a direction from the first end 211 to the second end 213. At least two second electrical connection ends 214 are distributed in a stepped manner, so that at least two second electrical connection ends 214 are staggered in a direction from the first end 211 to the second end 213.

[0127] The first electrical connection end 212 and the second electrical connection end 214 are both structures for electrically connecting the adapter 20 to other conductors. In one example, the first electrical connection end 212 is a threaded hole structure, so that a bolt can pass through the through hole on the wire nose 27 and cooperate with the threaded hole, thereby connecting the wire nose 27 (i.e., an embodiment of the other conductor mentioned above) to the circuit inside the adapter 20. In another example, the first electrical connection end 212 is a metal conductor row structure, so that the wire can be welded to the metal conductor row, or other conductive rows can be welded to the metal conductor row, thereby connecting other conductors to the circuit inside the adapter 20. The first electrical connection end 212 and the second electrical connection end 214 are set in a one-to-one correspondence. In some embodiments, it can be understood as a corresponding setting of the spatial position. In one example, please refer to Figure 2 and Fig. 27It can be seen that the first electrical connection terminal 212 and the second electrical connection terminal 214 correspond one-to-one in the direction from the first accommodating cavity 14 to the second accommodating cavity 15, so that the first electrical connection terminal 212 and the second electrical connection terminal 214 can be arranged neatly, which is convenient for the assembler of the controller 1000 to distinguish which second electrical connection terminal 214 corresponds to a specific first electrical connection terminal 212, thereby avoiding wiring errors. In general, the one-to-one correspondence between the first electrical connection terminal 212 and the second electrical connection terminal 214 can be understood as a first electrical connection terminal 212 being electrically connected to a specific second electrical connection terminal 214, so that when a first electrical connection terminal 212 is connected, it is electrically connected to a specific second electrical connection terminal 214, and the transfer function of the adapter 20 can be completed.

[0128] At least two first electrical connection ends 212 are staggered in the direction from the first end 211 to the second end 213 so that different conductors connected to different first electrical connection ends 212 do not interfere with each other in space; similarly, at least two second electrical connection ends 214 are staggered in the direction from the first end 211 to the second end 213 so that different conductors connected to different second electrical connection ends 214 do not interfere with each other in space, thereby facilitating the assembly of the adapter 20.

[0129] Please refer to Fig.13 , Fig.17 , Fig.18 and Fig.25 In some embodiments, the controller 1000 further includes a relay 600. The housing 10 further includes a partition wall 16 connected to the side wall 11. The partition wall 16 is used to separate the first accommodating chamber 14 and the second accommodating chamber 15. The relay 600 is disposed in the first accommodating chamber 14 and / or the second accommodating chamber 15. The relay 600 includes an access portion 610 and a drive portion 620. The access portion 610 is used to access a circuit controlled by the relay 600. The drive portion 620 is used to control the access portion 610 to be connected or disconnected. The arrangement direction of the access portion 610 and the drive portion 620 is perpendicular to the surface normal of the partition wall 16.

[0130] The relay 600 is a device for controlling the on and off of a circuit. The access part 610 of the relay 600 is the part that is actually connected to the circuit that needs to be controlled by the relay 600, and the driving part 620 is the part that can drive the circuit in the access part 610 to be disconnected or connected. In one example, the driving part 620 has a conductive element that can be attracted by a magnet (for example, an element made of a ferromagnetic material, or an element made of a permanent magnet), and an electromagnet is arranged in the driving part 620; when the electromagnet of the driving part 620 does not pass current, the conductive element is not connected to the remaining circuits in the access part 610, so the remaining circuits are not turned on and are in a short-circuit state; when the electromagnet of the driving part 620 is energized and attracts the conductive element, the conductive element is connected to the remaining circuits in the access part 610, so that the remaining circuits are turned on. When the circuit in the access part 610 is disconnected, the external circuit connected to the access part 610 is also disconnected; when the circuit in the access part 610 is connected, the external circuit connected to the access part 610 is also connected, thereby realizing the control of the on and off of the external circuit.

[0131] The access portion 610 and the drive portion 620 are often the larger parts. In the arrangement direction of the access portion 610 and the drive portion 620, the size of the relay 600 is the largest, or it is considered that the relay 600 often extends along the arrangement direction of the access portion 610 and the drive portion 620. The arrangement direction of the access portion 610 and the drive portion 620 is perpendicular to the surface normal of the partition wall 16, that is, Fig.25 The state shown (please refer to the diagram of the access unit 610 and the drive unit 620) Fig.17 ), it can be seen that in this embodiment, the relay 600 is installed in the box body 10 in a "lying" manner, so as not to occupy the space in the direction perpendicular to the surface of the partition wall 16, further optimizing the spatial layout of the components in the controller 1000.

[0132] Please refer to Fig.13 and Fig.14 In some embodiments, the control component 300 of the controller 1000 also includes a capacitor component 40. The relay 600 is disposed on the capacitor component 40. The capacitor component 40 is used to be electrically connected to a DC power supply outside the controller 1000. Since in some embodiments of the present application, the capacitor component 40 has a certain power distribution function, the controller 1000 needs to have a certain control capability over the circuit on the capacitor component 40. Therefore, the capacitor component 40 can cooperate with the relay 600, and the relay 600 can be connected to the circuit inside the capacitor component 40, thereby controlling the internal circuit of the capacitor component 40. The relay 600 is installed on the capacitor component 40. On the one hand, there is no need to set an additional mounting structure for the relay 600 in the box 10, which can save the installation space in the box 10. On the other hand, the relay 600 is closer to the internal circuit of the capacitor component 40, which can shorten the connection between the relay 600 and the capacitor component 40. In one example, Fig.14 As shown, the relay 600 is directly electrically connected to the first negative relay terminal 4010 and the second negative relay terminal 4011 on the capacitor assembly 40 through the relay conductive bar 640, thereby being connected to the internal circuit of the capacitor assembly 40. It can be seen that the above embodiment can further optimize the spatial layout of various components in the controller 1000.

[0133] Please refer to Fig. 9 , Fig.13 and Fig.14 In some embodiments, the capacitor assembly 40 includes a first housing 41. The relay 600 is a housingless relay 600. The housingless relay 600 and the first housing 41 are integrally injection molded.

[0134] The first housing 41 of the capacitor assembly 40 is the supporting structure of the capacitor assembly 40. The electronic components in the capacitor assembly 40 are mounted on the first housing 41. For example, the capacitor in the capacitor assembly 40 (eg Fig.24 The boost capacitor 4017 shown is installed on the first housing 41. However, in the embodiment shown in the accompanying drawings, the capacitor is wrapped in the first housing 41, so the capacitor is not shown in the structural diagram in the accompanying drawings. The shellless relay 600 has no shell, so the volume is smaller. The shellless relay 600 and the first housing 41 are integrally injection molded, and the first housing 41 can also serve as the shell of the shellless relay 600, that is, the installation of the shellless relay 600 is completed, and the shellless relay 600 is protected. In summary, the shellless relay 600 is integrally injection molded with the first housing 41, and the insurance support seat 411 is integrally molded with the first housing 41, which can reduce the installation space required for the capacitor assembly 40 and the relay 600 as a whole, and further optimize the spatial layout of various components in the controller 1000.

[0135] The fuse 32 can be blown when the current is too large to disconnect the circuit and protect the components on the circuit. Figure 1 , Fig. 9 , Fig.13 ,and Fig.24, the positive and negative currents of the DC bus pass through the positive insurance transfer terminal 402 and the negative insurance transfer terminal 406 respectively, and then pass through two insurances 32 respectively, and then enter the capacitor assembly 40 through the bus capacitor positive terminal 401 and the boost capacitor negative terminal 407, and finally output to the module drive motor 3000 through the capacitor assembly 40. It can be seen that in this example, the positive and negative currents of the drive motor 3000 pass through a fuse 32 respectively, so the fuse 32 can prevent the current of the drive motor 3000 from being too large, causing damage to the components on the drive circuit. In some embodiments, the insurance support seat 411 is also integrally formed with the first housing 41, so there is no need to set a split insurance support seat 411, so that the installation space required for the insurance 32 is reduced. The insurance support seat 411 is a structure for installing the insurance 32.

[0136] Please refer to Fig.13 , Fig.17 , Fig.18 and Fig.25 In some embodiments, the relay 600 extends along a first direction that is perpendicular to the surface normal of the partition wall 16 .

[0137] That is, the relay 600 is in the state of Fig.25 From the state shown, it can be seen that in this embodiment, the direction in which the relay 600 extends is perpendicular to the surface normal of the partition wall 16, which is equivalent to the relay 600 being installed in the box body 10 in a "lying" manner, so that the space in the direction perpendicular to the surface of the partition wall 16 is not occupied, and the spatial layout of the components in the controller 1000 is further optimized. When the controller 1000 is applied to a vehicle, the surface normal of the partition wall 16 is generally along the Z-axis direction of the vehicle, so the relay 600 can be placed horizontally to avoid occupying the installation space in the Z direction.

[0138] Please refer to Fig. 9 , Fig.13 , Fig.14 , Fig.15 and Fig.16 In some embodiments, the control component 300 further includes a transfer plate 311, and the transfer plate 311 is electrically connected to the capacitor component 40 by welding. Fig.15 , directly connecting by welding can make the distance between the adapter plate 311 and the capacitor closer, because the welding connection does not require an additional wire harness 500 or a conductive bar, and the adapter plate 311 can be directly welded to the conductive bar on the capacitor assembly 40. In this way, the overall installation space of the control board 35 and the capacitor assembly 40 can be reduced, thereby further optimizing the spatial layout of various components in the controller 1000.

[0139] Please refer to Fig. 9 , Fig.13 , Fig.14 , Fig.15 and Fig.16 In some embodiments, the capacitor assembly 40 includes a sampling conductive row 42, and the sampling conductive row 42 is electrically connected to the circuit in the capacitor assembly 40. For details, please refer to Fig.24 There can be multiple sampling conductive bars 42, and the multiple sampling conductive bars 42 can be respectively connected to the DC bus negative voltage sampling point 4012, the DC bus positive voltage sampling point 4013, the N line voltage sampling point 4014 and the DC charging and negative sampling point 4015, thereby providing Fig.24 The circuit information (e.g., voltage information) of each sampling point shown in the figure can be obtained by the control board 35. This makes it easier for the control board 35 to monitor the circuit information of each sampling point, thereby controlling the circuit in the controller 1000. The adapter board 311 can be welded to the sampling conductive bar 42, so that the adapter board 311 can obtain the circuit information of the sampling point by itself (when the adapter board 311 plays a control role), or the control board 35 can obtain the circuit information of the sampling point through the adapter board 311 (when the control board 35 plays a control role and the adapter board 311 only plays a transfer role).

[0140] Please refer to Fig. 9 , Fig.10 , Figures 13 to 20 and Figure 22 to Figure 24 In some embodiments, the controller 1000 is formed with a charging circuit, a boost circuit, a current boost circuit, and a heating circuit. The charging circuit, the boost circuit, the current boost circuit, and the heating circuit are at least partially formed on the capacitor assembly 40. The charging circuit is used to transfer the DC power supply to the battery connected to the controller 1000. The boost circuit is used to increase the voltage of the DC power supply and then transfer it to the battery connected to the controller 1000. The current boost circuit is used to increase the current of the DC power supply and then transfer it to the battery connected to the controller 1000. The heating circuit is used to heat the electrical system connected to the controller 1000.

[0141] The charging circuit is the aforementioned "circuit in which the current input by the DC charging filter 80 is directly used for battery charging". Please refer to the above text for details.

[0142] The boost circuit is the abbreviation of the boost charging circuit. When the voltage input by the DC charging filter 80 is small and cannot meet the voltage requirement for charging the battery, the voltage needs to be increased and then connected to the battery to charge the battery. In an example, the current flow of the boost circuit can be as follows: the current flows into the DC charging line positive electrode interface 801, and then flows to the DC boost charging positive electrode input interface 803 through the conductive bus. At this time, the current is divided into two paths. One path flows directly to the capacitor boost positive electrode conductive bus interface 805 through the conductive bus, and then flows to the DC charging boost capacitor positive electrode terminal 408 and the boost charging positive electrode N line adapter terminal 409, and then flows into the capacitor component 40. The control board 35 (or adapter board 311) will control at this time. Fig.18The relay 600 on the right side is turned on, so that another current flows to the first DC charging positive electrode output interface 804, and then flows to the capacitor N line conductive row interface 806 through the conductive row, and then enters the capacitor assembly 40. A boost capacitor 4017 is provided in the capacitor assembly 40, and the capacitor assembly 40 is also connected to the motor 3000 through the power device module 70 and the three-phase conductive row assembly 50. Therefore, the boost capacitor 4017 in the capacitor assembly 40, the power device in the power device module 70 and the stator winding of the motor 3000 can be used as a boost capacitor, switch and inductor in the boost boost circuit respectively, so as to complete the boosting effect through the boost circuit; and then flow to the positive electrode of the battery through the DC bus filter 60, and the current then flows from the negative electrode of the battery through the DC bus filter 60 to the negative electrode interface 802 of the DC charging line, forming a boost charging closed loop circuit.

[0143] The boost circuit is the abbreviation of the boost charging circuit. When the voltage input to the DC charging filter 80 is large, the voltage needs to be reduced. In an example of the boost circuit, the boost circuit can be the same as the boost circuit, except that the boost circuit is replaced by a buck circuit. Since the input power of the external power supply remains unchanged, the current will increase if the voltage is reduced, so the buck circuit can be used to play the role of boost charging.

[0144] The heating circuit is a circuit formed when the ambient temperature is low and the entire electrical system of the vehicle needs to be heated. In one example, the self-heating circuit can be formed in the following way: the output current of the upper half of the battery pack enters the controller 1000 from the positive pole of the DC bus, flows through the positive pole fuse adapter terminal 402, the fuse 32 connected to the positive pole fuse adapter terminal 402, and the positive terminal 401 of the bus capacitor into the capacitor assembly 40, and then flows into the power device module 70. The self-heating current generated in the power device module 70 flows into the motor 3000 through the three-phase conductive bus to charge the inductance inside the motor 3000. The inductor current flows through the N line adapter terminal 405 and the N line 312 to the DC bus boost conductive bus 65, enters the DC bus filter, and then flows into the lower half of the battery pack, thereby generating heat and completing self-heating.

[0145] In summary, each circuit is partially formed on the capacitor assembly 40 , which improves the integration of the controller 1000 , thereby reducing the controller 1000 's requirement for installation space, or reducing the volume of the controller 1000 .

[0146] Please refer to Figure 5 , Fig.10 and Fig.24In some embodiments, the capacitor assembly 40 is also used to be electrically connected to a battery outside the controller 1000. The capacitor assembly 40 also includes a power distribution conductive bar 43, which is electrically connected to a DC power source and / or a battery, and the power distribution conductive bar 43 is also electrically connected to the power supply assembly 400 of the controller 1000.

[0147] The battery outside the controller 1000 can be a power battery of the vehicle. The DC power supply is a power supply outside the controller 1000 that can input current into the controller 1000, for example, it can also be other batteries, or charging piles, etc. The distribution conductive bar 43 is electrically connected to the power supply assembly 400, so the distribution conductive bar 43 can input current to the power supply assembly 400. Since the distribution conductive bar 43 is electrically connected to the DC power supply and / or the battery, the distribution conductive bar 43 can draw power from the battery and / or the DC power supply, thereby supplying power to the power supply assembly 400. The distribution copper bus can draw power from the battery through the DC bus filter 60, and can draw power from the DC power supply through the DC charging filter 80. The specific electrical connection method can be referred to above.

[0148] In summary, the capacitor assembly 40 can integrate some power distribution functions, thereby improving the integration level of the capacitor assembly 40 .

[0149] Please refer to Figure 1 , Figure 5 , Fig.10 and Fig.24 In some embodiments, the capacitor assembly 40 includes a power distribution fuse 44, which is connected in series in the circuit to which the power distribution conductive bar 43 is connected.

[0150] Specifically, the power distribution conductive bar 43 may include a positive power distribution bar 431, a fuse transfer bar 432 and a negative power distribution bar 433. Fig.10 and Fig.24 It can be seen that the insurance transfer bar 432 is electrically connected to the positive poles of the DC bus filter 60 and the DC charging filter 80 (interval with the relay 600), and the positive distribution bar 431 is electrically connected to the insurance transfer bar 432 through the distribution insurance 44, so that the positive distribution bar 431 can be electrically connected to two DC power sources (the external DC power source connected to the DC charging filter 80 and the battery connected to the DC bus filter 60); and the negative distribution bar 433 is electrically connected to the negative poles of the DC charging filter 80 and the DC bus filter 60. In this way, the positive distribution bar 431 and the negative distribution bar 433 can draw power from the two DC power sources, and the distribution insurance 44 can disconnect the positive distribution bar 431 from the positive pole of the power source when the current is too large to ensure circuit safety.

[0151] Please refer to Fig.11 , Fig.12 and Fig.24In some embodiments, the control component 300 of the controller 1000 further includes a power device module 70 , and the capacitor component 40 is electrically connected to the power device module 70 .

[0152] The capacitor component 40 is electrically connected to the power device module 70 , so that the output current of the capacitor component 40 can flow directly into the power device module 70 , thereby avoiding current loss caused by an excessively long circuit and improving the working efficiency of the controller 1000 .

[0153] Specifically, the power device module 70 may include a laser-welded overlapping conductive bar 71 and a high-temperature resistant insulating partition 72, wherein the laser-welded overlapping conductive bar 71 is provided with a detection hole 711 and a positioning hole 712. The capacitor assembly 40 may include a laser-welded negative electrode conductive bar 45, a laser-welded positive electrode conductive bar 46 and a baffle 47. The laser-welded overlapping conductive bar 71 is responsible for electrically connecting the power device module 70 and the negative electrode of the capacitor assembly 40. The high-temperature resistant insulating partition 72 separates the laser-welded overlapping copper bar from the capacitor assembly 40 and / or other parts of the power device module 70 during the welding operation to prevent the high temperature of welding from damaging other structures. The laser-welded overlapping conductive bar 71 will be welded with the laser-welded negative electrode conductive bar 45, and the detection hole 711 is a detection hole 711 for detecting whether the laser-welded overlapping conductive bar 71 and the laser-welded negative electrode conductive bar 45 are appropriately spaced before welding. A positioning post may be provided on the power device module 70 or the capacitor assembly 40, so that the positioning post can be inserted into the positioning hole 712 of the high temperature resistant insulating partition 72 and the laser welded overlapping conductive bar 71, thereby positioning the high temperature resistant insulating partition 72 and the laser welded overlapping conductive bar 71. The laser welded positive conductive bar is a conductive bar that is electrically connected to the positive electrode of the power device module 70. The baffle 47 can separate the laser welded negative conductive bar 45 and the laser welded positive conductive bar 46 to prevent the two from contacting and causing a short circuit.

[0154] In addition, a baffle positioning hole 4016 can be provided on the baffle 47. During the manufacturing process of the capacitor assembly 40, the laser-welded conductive bar at the capacitor end can be positioned through the baffle positioning hole 4016 to ensure that the position of the laser-welded conductive bar of the capacitor assembly 40 will not be offset. Before the welding operation, the power device module 70 can be fixed on the box 10 or the tooling, and then the capacitor assembly 40 can be assembled. The laser-welded positive conductive bar 46 will be connected to the positive conductive bar of the power device module 70 after the capacitor assembly 40 is installed and fixed. After the pre-welding gap detection is performed through the detection hole 711, welding can be started. After the positive conductive bar is welded, the laser-welded lap copper bar can be placed on the negative conductive bar of the capacitor assembly 40 and the negative conductive bar of the power device module 70.

[0155] exist Fig.11In the embodiment shown, the laser welded overlapped conductive bar 71 is positioned through the positioning hole 712. Because the laser welded overlapped conductive bar 71 is relatively long, two detection holes 711 are added to the laser welded overlapped conductive bar 71 to facilitate the gap detection between the laser welded negative electrode conductive bar 45 and the laser welded overlapped conductive bar 71. After the detection is completed, welding can be performed. At the same time, considering the safety requirements and welding requirements, high temperature resistant insulating material, that is, high temperature resistant insulating partition 72, is added to the inner side of the laser welded overlapped conductive bar 71 for protection. The laser welded overlapped conductive bar 71 can be a copper bar with a model of TU1.

[0156] Please refer to Fig.11 , Fig.12 and Fig.24 In some embodiments, the capacitor assembly 40 is connected to the power device module 70 by laser welding.

[0157] The capacitor assembly 40 and the power device module 70 are connected by laser welding, which can reduce assembly time and enhance the automated production capability of the controller 1000 . Laser welding can effectively reduce stray inductance and improve the performance of the capacitor assembly 40 .

[0158] Please refer to Fig.17 , Fig.18 , Fig.19 and Fig.24 In some embodiments, the control component 300 of the controller 1000 further includes a DC charging filter 80. The relay 600 is disposed on the DC charging filter 80. The DC charging filter 80 is used to be electrically connected to an external DC power supply of the controller 1000.

[0159] The setting of relay 600 enables controller 1000 to control whether the external DC power supply is connected or not. That is, when the control system inside controller 1000 detects that the DC power supply outside controller 1000 does not meet the connection requirements, such as the voltage is too high or the current is too low, or it is found through detection that the external DC power supply is an illegal power supply (a power supply that does not meet national standards), the DC power supply can be refused to be connected to controller 1000 by disconnecting relay 600, thereby protecting the components inside controller 1000 and connected to controller 1000. Please refer to Fig.17 In some embodiments, a first limiting portion 83 and a second limiting portion 84 can be provided on the housing of the DC charging filter 80, and both limit the relay 600 from both sides of the relay 600 respectively, and provide guidance for the relay 600 during installation, thereby improving the assembly efficiency of the relay 600.

[0160] Please refer to Fig.16 , Fig.17 , Fig.18 , Fig.19and Fig.24 In some embodiments, the controller 1000 is formed with a charging circuit and a boost circuit. At least part of the charging circuit and the boost circuit are arranged on the DC charging filter 80. Two relays 600 are arranged on the DC charging filter 80. The two relays 600 are respectively connected to the charging circuit and the boost circuit.

[0161] The charging circuit and boost circuit are explained above. Please refer to the above for details. Fig.24 Due to the setting of the two relays 600, the controller 1000 can selectively turn on the charging circuit or the boost circuit (in practice, it is usually not necessary for the two circuits to work at the same time, because when the DC power supply meets the requirements, the charging circuit is used, and when the DC power supply does not meet the requirements, the boost circuit is used). In addition, please refer to Fig.16 and Fig.19 The two relays 600 installed on the DC charging filter 80 can also be welded to the adapter plate 311. At the same time, the relays 600 installed on the capacitor assembly 40 can also be welded to the adapter plate 311. Since the capacitor assembly 40 and the DC charging filter 80 can be electrically connected to each other through the conductive bar, this arrangement can reduce the total volume of the adapter plate 311, the capacitor assembly 40 and the DC charging filter 80, making the arrangement of the components in the controller 1000 more compact. Fig.16 and Fig.19 In the illustrated embodiment, it can be seen that the portion where the relay 600 is welded to the adapter board 311 is the control signal pin 630 of the relay 600, so that the adapter board 311 can control the relay 600 through the control signal pin 630, that is, control the relay 600 to be turned on or off.

[0162] Please refer to Figure 1 and Fig.21 In some embodiments, the control assembly 300 of the controller 1000 includes a three-phase conductive bar assembly 50. The three-phase conductive bar assembly 50 is used to be electrically connected to the power device module 70 of the control assembly 300. The three-phase conductive bar assembly 50 includes a second housing 51, a U-phase conductive bar 52, a V-phase conductive bar 53, a W-phase conductive bar 54, and a first filter magnetic ring 55. The second housing 51, the U-phase conductive bar 52, the V-phase conductive bar 53, the W-phase conductive bar 54, and the first filter magnetic ring 55 are integrally injection molded.

[0163] The first filter magnetic ring 55 can be a filter magnetic ring such as a ferrite magnetic ring or a nanocrystalline magnetic ring. The first filter magnetic ring 55 can filter out interference signals of the three-phase alternating current carried by the U-phase conductive bar 52, the V-phase conductive bar 53 and the W-phase conductive bar 54, thereby improving the stability of the output current of the three-phase conductive bar assembly 50. The second housing 51, the U-phase conductive bar 52, the V-phase conductive bar 53, the W-phase conductive bar 54 and the first filter magnetic ring 55 are integrally injection molded to improve the manufacturing efficiency of the three-phase conductive bar assembly 50. At the same time, since there is no need to set up an additional insulating rubber part (the insulating jacket required for the U-phase conductive bar 52, the V-phase conductive bar 53 and the W-phase conductive bar 54), the volume of the three-phase conductive bar assembly 50 can be reduced.

[0164] Please refer to Figure 1 and Fig.21 In some embodiments, the control component 300 of the controller 1000 includes a three-phase conductive bar component 50. The three-phase conductive bar component 50 is used to be electrically connected to the power device module 70 of the control component 300. The three-phase conductive bar component 50 includes a second housing 51, a U-phase conductive bar 52, a V-phase conductive bar 53, a W-phase conductive bar 54 and a first filter magnetic ring 55. The U-phase conductive bar 52, the V-phase conductive bar 53, the W-phase conductive bar 54 and the first filter magnetic ring 55 are all arranged on the second housing 51. The U-phase conductive bar 52, the V-phase conductive bar 53 and the W-phase conductive bar 54 are in a strip shape. The U-phase conductive bar 52, the V-phase conductive bar 53 and the W-phase conductive bar 54 are arranged in parallel with each other and are arranged at intervals in a direction perpendicular to the length direction of the U-phase conductive bar 52. The first filter magnetic ring 55 is arranged at the output end of the U-phase conductive bar 52, the V-phase conductive bar 53 and the W-phase conductive bar 54.

[0165] Please refer to Fig.21 The three-phase conductive bar assembly 50 using the above layout can be approximately plate-shaped. Figure 1 , Fig.21 and Fig.26 The plate-shaped three-phase conductive bar assembly 50 can be arranged in parallel with the partition wall 16, thereby reducing the height of the three-phase conductive bar assembly 50 in a direction perpendicular to the surface of the partition wall 16, so that the components in the controller 1000 can be arranged more compactly.

[0166] Please refer to Fig. 22 and Fig.23 In some embodiments, the control component 300 of the controller 1000 includes a DC bus filter 60. The DC bus filter 60 is used to be electrically connected to the capacitor component 40 of the control component 300. The DC bus filter 60 includes an X capacitor 61, a Y capacitor 62, and a second filter magnetic ring 63, and the X capacitor 61, the Y capacitor 62, and the second filter magnetic ring 63 are all used to filter the circuit connected to the DC bus filter 60.

[0167] The X capacitor 61 can filter the differential mode interference signal in the circuit connected to the DC bus filter 60, the Y capacitor 62 can filter the common mode interference signal in the circuit connected to the DC bus filter 60, and the second filter magnetic ring 63 can be a filter magnetic ring such as a ferrite magnetic ring or a nanocrystalline magnetic ring, which can filter the high-frequency interference signal in the circuit connected to the DC bus filter 60. More than one X capacitor 61 and more than one Y capacitor 62 can be set, and more than one group can be formed. A group of X capacitors 61 includes at least two X capacitors 61, and a group of Y capacitors 62 includes at least two Y capacitors 62; the X capacitors 61 in the same group of X capacitors 61 can be connected in series, in parallel, or in mixed connection to meet the combined capacitance size requirements and the withstand voltage requirements; the Y capacitors 62 in the same group of Y capacitors 62 can be connected in series, in parallel, or in mixed connection to meet the combined capacitance size requirements and the withstand voltage requirements. Since the X capacitor 61 , the Y capacitor 62 and the second filter magnetic ring 63 are used for filtering, the controller 1000 can meet a higher level of electromagnetic compatibility (EMC) to meet the EMC requirements of SiC power devices or IGBTs.

[0168] Please refer to Fig.26 , Fig. 27 , Fig.28 , Fig.29 , Fig.30 , Fig.31 , Fig.32 , Fig.33 , Fig.34 and Fig.35 In some embodiments, the housing 10 is formed with a water channel 18. The water channel 18 is used for supercooling liquid. The coolant is used to dissipate heat from the power supply component 400 and the control component 300 of the controller 1000.

[0169] The water channel 18 of the box body 10 can be formed inside the side wall 11 and / or the partition wall 16, or can be formed on the surface of the side wall 11 and / or the partition wall 16. When the water channel 18 is formed on the surface of the side wall 11 and / or the partition wall 16, a cover plate 110 and the side wall 11 and / or the partition wall 16 can be set to enclose the water channel 18 to prevent the coolant from overflowing.

[0170] The provision of the water channel 18 can dissipate heat for the power supply component 400 and the control component 300 , thereby preventing the power supply component 400 and the control component 300 from overheating and protecting the power supply component 400 and the control component 300 .

[0171] Please refer to Figure 26 to Figure 35 In some embodiments, a guide rib 19 is disposed in the water channel 18, and the guide rib 19 extends along the flow direction of the water channel 18. The water channel 18 has at least one bend. The guide rib 19 is at least partially disposed at the bend of the water channel 18.

[0172] exist Fig.32 and Fig.33 In the illustrated embodiment, it can be seen that the water channels 18 such as the first water channel 181 and the second water channel 183 are flat, which can expand the distribution area of ​​the water channel 18 in the box 10, so as to contact more components and dissipate heat for more components. The provision of the guide ribs 19 can allow the coolant to be more evenly distributed to various locations in the width direction of the water channel 18, thereby improving the heat dissipation effect of the water channel 18. In addition, the coolant may have a high flow rate, and the provision of the guide ribs 19 can prevent the high-flow coolant from directly impacting the side of the water channel 18 in the width direction at the bend of the water channel 18, thereby preventing the coolant from breaking through the constraints of the water channel 18 from the side of the water channel 18 in the width direction and leaking.

[0173] Please refer to Figure 26 to Figure 35 In some embodiments, the housing 10 further includes a partition wall 16 and a cover plate 110 connected to the side wall 11. The partition wall 16 is used to separate the first accommodating chamber 14 from the second accommodating chamber 15. The control component 300 is disposed in the first accommodating chamber 14. The power supply component 400 is disposed in the second accommodating chamber 15. The cover plate 110 and the partition wall 16 enclose a waterway 18.

[0174] exist Figure 1 In the embodiment shown, please refer to Fig.26 The cover plate 110 is equivalent to forming a part of the bottom wall of the first accommodating cavity 14. Fig.25 and Fig.26 It can be seen that the discharge plate 31, the driving plate 38 (and the power device module 70 blocked by the driving plate 38) and the capacitor assembly 40 can all be disposed on the cover plate 110, so as to dissipate heat through the water channel 18. It can be understood that in other embodiments, the cover plate 110 can have a larger area, so as to dissipate heat for more components.

[0175] In one example, the coolant in the water channel 18 may flow in the following manner:

[0176] Please refer to Fig.26 The coolant enters the water channel 18 through the water inlet pipe 184 provided on the side wall 11. Fig.28 , Fig.30 and Fig.32 , the coolant enters the first water channel 181 after passing through the water inlet pipe 184. Please refer to Fig.33 , the coolant flows out of the first water channel 181 through the water channel outlet 188. Please refer to Fig.35The coolant flows into the power water channel 182 through the water channel outlet 188. The power water channel 182 may be the water channel 18 formed by the IGBT module 430 of the power assembly 400 and the partition wall 16. In this way, the power water channel 182 can dissipate heat for the IGBT module 430. In addition, on the side of the power assembly 400, the water channel 18 can also dissipate heat for the transformer and MOS tube components of the power assembly 400. Please refer to Fig.32 and Fig.35 , the coolant flows out of the power water channel 182 from the water channel inlet 189 and flows into the second water channel 183. Please refer to Fig.33 and Fig.34 The coolant flows out of the second water channel 183 under the action of the second water distribution plate 187 and enters the cover plate water channel 1103 through the cover plate inlet 1101. The cover plate water channel 1103 may be the water channel 18 formed by the power device module 70 and the cover plate 110. Therefore, the cover plate water channel 1103 can dissipate heat for the power device module 70. Please refer to Fig.29 , Fig.33 and Fig.34 The coolant flows out of the cover plate water channel 1103 through the cover plate outlet 1102, and flows into the outlet channel 1810 through the cover plate outlet 1102. The outlet channel 1810 is the water channel 18 formed by the first water distribution plate 186 and the cover plate 110. The outlet channel 1810 is connected to the outlet pipe 185, so the coolant can flow into the outlet pipe 185 through the outlet channel 1810 and then flow out of the controller 1000, completing a cooling effect. After flowing out of the controller 1000, the coolant can enter the motor 3000 to dissipate heat for the motor 3000.

[0177] Please refer to Fig.26 and Fig.32 In some embodiments, the cover plate 110 and the partition wall 16 are fixedly connected by friction welding.

[0178] The friction welding method can weld the water channel 18 cover plate 110 and the box body 10 tightly together, effectively reducing the risk of water leakage in the water channel 18.

[0179] Please refer to Figures 1 to 27 To further demonstrate Figure 1 The implementation method in the controller 1000 optimizes the spatial layout of each component, providing a Figure 1 The assembly process of the electric control box 10 of the embodiment is as follows:

[0180] The controller 1000 can be adapted to an automated production line. First, install the water inlet pipe 184 on the housing 10, laser weld the power device module 70 and the capacitor assembly 40 together, then place the power device module 70 and the capacitor assembly 40 in the first accommodating chamber 14, pre-install the three-phase conductive bar assembly 50 in the Hall assembly 33, and install the pre-installed Hall assembly 33 and the three-phase conductive bar assembly 50 at the output end of the power device module 70; then install the drive board 38 and the control board shielding plate 34 in sequence, and the low-voltage connector 410 (not shown) must first be welded to the control board 35, and then installed above the control board shielding plate 34; install the DC bus filter 60 and the DC charging filter 80 on the capacitor assembly 40 in sequence, and also install the fuse 32 on the capacitor assembly 40, Install the DC charging negative input conductive bar 39 on the capacitor assembly 40 and the DC bus filter 60; install the N line conductive bar adapter 36 on the box 10, and install the N line-three-phase adapter 37 on the N line conductive bar adapter 36; install the adapter 20 in the box 10; install the adapter board 311 above the DC charging filter 80 and the capacitor assembly 40, and connect the adapter board 311 and the control board 35 through the wiring harness; install the DC charging terminal 85 on the DC charging filter 80, and the three-core wire nose 310 on the DC bus filter 60, and finally fix the electric control upper cover 112, the three-phase small cover 113, the busbar small cover 115, and the DC charging small cover 114, and the assembly of the controller 1000 is completed. Figure 1 The controller 1000 in the embodiment has high assembly efficiency and simple process. Figure 1 The controller 1000 of the implementation scheme improves the assembly efficiency of the controller 1000 by optimizing the spatial layout of various components in the controller 1000 .

[0181] Please refer to Fig.36 and Fig.37 The electric assembly 10000 of the embodiment of the present application includes the controller 1000 of any of the above embodiments, and therefore has all the beneficial effects of the controller 1000 in the above embodiments, which will not be repeated here.

[0182] Please refer to Fig.36 and Fig.37In some embodiments, the electric assembly 10000 also includes a motor 3000 and a reducer 2000 connected to each other. The housing 10 also includes a partition wall 16 connected to the side wall 11. The partition wall 16 is used to separate the first accommodating chamber 14 and the second accommodating chamber 15. The side wall 11 includes a first side wall 12 and a second side wall 13. The first side wall 12 and the partition wall 16 are used to form the first accommodating chamber 14. The second side wall 13 and the partition wall 16 are used to form the second accommodating chamber 15. The partition wall 16 is connected to the motor 3000 and the reducer 2000. The first side wall 12 is arranged on the side of the partition wall 16 facing away from the motor 3000. The second side wall 13 is arranged on the side of the partition wall 16 facing the motor 3000, and is located in the space enclosed by the motor 3000 and the reducer 2000; the controller 1000 also includes a power supply assembly 400, which is arranged in the second accommodating chamber 15.

[0183] In this way, the second accommodating chamber 15 can utilize the space between the motor 3000 and the reducer 2000, thereby improving the space utilization of the electric assembly 10000, thereby reducing the total volume of the electric assembly 10000 and improving the torque density of the electric assembly 10000.

[0184] In some embodiments, the motor 3000 includes a first housing and a rotor, the reducer 2000 includes a second housing and a reduction mechanism, the rotor is arranged in the first housing, and the reduction mechanism is arranged in the second housing. The first housing, the second housing and the housing 10 are integrally formed. The reduction mechanism is a mechanism for reducing the output speed of the motor rotor before outputting it. The first housing, the second housing and the housing 10 are integrally formed, and can be integrally formed by casting, forging, 3D printing or CNC machining, etc., so as to improve the connection strength between the three, while reducing the connection structure between the three, so that the structure of the electric assembly 10000 is more compact.

[0185] The vehicle of the embodiment of the present application includes the controller of any of the above embodiments or the electric assembly of any of the above embodiments, and therefore has all the beneficial effects of the controller or the electric assembly in the above embodiments, which will not be repeated here. The vehicle of the embodiment of the present application can be a new energy vehicle, a hybrid vehicle or a fuel vehicle, and the present application does not limit this.

[0186] The technical features of the above-mentioned embodiments can be combined arbitrarily. To make the description concise, not all possible combinations of the technical features in the above-mentioned embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification. At the same time, other embodiments can be derived from the above-mentioned embodiments, so that structural and logical replacements and changes can be made without departing from the scope of this disclosure.

[0187] The above-mentioned embodiments only express several embodiments of the present application, and the description is relatively specific and detailed, but it cannot be understood as limiting the scope of the patent. It should be pointed out that for ordinary technicians in this field, several modifications and improvements can be made without departing from the concept of the present application, which all belong to the protection scope of the present application. Therefore, the protection scope of the patent of this application shall be based on the attached claims.

Claims

1. A controller (1000), characterized in that: include: The box body (10) comprises a side wall (11); the side wall (11) surrounds and forms a first accommodating cavity (14) and a second accommodating cavity (15); and The adapter (20) is arranged on the inner side of the side wall (11) and comprises a first end (211) and a second end (213) opposite to each other; the first end (211) extends into the first accommodating cavity (14), and the second end (213) extends into the second accommodating cavity (15).

2. The controller (1000) according to claim 1, characterized in that: The box body (10) further comprises a partition wall (16) connected to the side wall (11); the partition wall (16) is used to separate the first accommodating cavity (14) and the second accommodating cavity (15); and the adapter (20) is disposed through the partition wall (16).

3. The controller (1000) according to claim 2, characterized in that: The side wall (11) comprises a first side wall (12) and a second side wall (13); the first side wall (12) and the second side wall (13) are respectively arranged on both sides of the partition wall (16); the first side wall (12) and the partition wall (16) are used to form the first accommodating cavity (14); the second side wall (13) and the partition wall (16) are used to form the second accommodating cavity (15).

4. The controller (1000) according to claim 2, characterized in that: The adapter (20) is fixedly connected to the box body (10).

5. The controller (1000) according to claim 4, characterized in that: The adapter (20) comprises an adapter portion (21) and a mounting portion (26) connected to each other, wherein the adapter portion (21) is used for circuit switching; and a through hole is provided on the mounting portion (26), wherein the through hole is used for fixed connection with the box body (10).

6. The controller (1000) according to claim 5, characterized in that: The adapter portion (21) is plate-shaped, and the mounting portion (26) comprises a first mounting portion (261) and a second mounting portion (262); the first mounting portion (261) and the second mounting portion (262) are respectively arranged on two opposite sides of the adapter portion (21).

7. The controller (1000) according to claim 1, characterized in that: One side surface of the plate-shaped adapter (20) faces the side wall (11) and is arranged adjacent to the side wall.

8. The controller (1000) according to claim 1, characterized in that: It also includes a control component (300) and a power component (400); the control component (300) is arranged in the first accommodating cavity (14); the power component (400) is arranged in the second accommodating cavity (15); the first end (211) of the adapter (20) is used to be electrically connected to the control component (300); and the second end (213) of the adapter (20) is used to be electrically connected to the power component (400).

9. The controller (1000) according to claim 8, characterized in that: The power supply assembly (400) comprises a connector (410), and the connector (410) is inserted into the box (10); the second end (213) is used to electrically connect to one end of the connector (410) located in the second accommodating cavity (15).

10. The controller (1000) according to claim 8, characterized in that: The control component (300) comprises a discharge plate (31), and the first end (211) is used for being electrically connected to the discharge plate (31).

11. The controller (1000) according to claim 8, characterized in that: The power supply component (400) comprises a filter board (420); the filter board (420) is electrically connected to a direct current circuit; the filter board (420) is also electrically connected to a discharge board (31) of the control component (300).

12. The controller (1000) according to claim 8, characterized in that: The first end (211) of the adapter (20) is electrically connected to the control component (300) via a wiring harness (500); and the second end (213) of the adapter (20) is electrically connected to the power supply component (400) via a wiring harness (500).

13. The controller (1000) according to claim 12, characterized in that: A wire nose (27) is provided on both the first end (211) and the second end (213) of the adapter (20), and the wire nose (27) is used to connect to the wire harness (500).

14. The controller (1000) according to claim 8, characterized in that: At least two first electrical connection ends (212) are provided on the first end (211) of the adapter (20); at least two second electrical connection ends (214) are provided on the second end (213) of the adapter (20); the first electrical connection ends (212) and the second electrical connection ends (214) are arranged in a one-to-one correspondence, and the corresponding first electrical connection ends (212) are electrically connected to the second electrical connection ends (214).

15. The controller (1000) according to claim 14, characterized in that: At least two of the first electrical connection ends (212) are distributed in a step-like manner, so that at least two of the first electrical connection ends (212) are distributed in a staggered manner in the direction from the first end (211) to the second end (213); and at least two of the second electrical connection ends (214) are distributed in a step-like manner, so that at least two of the second electrical connection ends (214) are distributed in a staggered manner in the direction from the first end (211) to the second end (213).

16. The controller (1000) according to claim 1, characterized in that: The invention also comprises a relay (600); the box body (10) further comprises a partition wall (16) connected to the side wall (11); the partition wall (16) is used to separate the first accommodating cavity (14) and the second accommodating cavity (15); the relay (600) is arranged in the first accommodating cavity (14) and / or the second accommodating cavity (15); the relay (600) comprises an access portion (610) and a drive portion (620); the access portion (610) is used to access a circuit controlled by the relay (600); the drive portion (620) is used to control the access portion (610) to be connected or disconnected; the arrangement direction of the access portion (610) and the drive portion (620) is perpendicular to the surface normal of the partition wall (16).

17. The controller (1000) according to claim 16, characterized in that: The control component (300) of the controller (1000) further comprises a capacitor component (40); the relay (600) is arranged on the capacitor component (40); and the capacitor component (40) is used to be electrically connected to a direct current power source outside the controller (1000).

18. The controller (1000) according to claim 17, characterized in that: The capacitor assembly (40) comprises a first housing (41); the relay (600) is a housing-less relay (600); and the housing-less relay (600) and the first housing (41) are integrally injection-molded.

19. The controller (1000) according to claim 16, characterized in that: The relay (600) extends along a first direction; the first direction is perpendicular to the surface normal of the partition wall (16).

20. The controller (1000) according to claim 17, characterized in that: A charging circuit, a voltage boosting circuit, a current boosting circuit and a heating circuit are formed; the charging circuit, the voltage boosting circuit, the current boosting circuit and the heating circuit are at least partially formed on the capacitor component (40); the charging circuit is used to transfer the DC power supply to a battery connected to the controller (1000); The voltage boost circuit is used to boost the voltage of the DC power supply and then transfer it to the battery connected to the controller (1000); the current boost circuit is used to boost the current of the DC power supply and then transfer it to the battery connected to the controller (1000); and the heating circuit is used to heat the electrical system connected to the controller (1000).

21. The controller (1000) according to claim 17, characterized in that: The capacitor assembly (40) is also used to be electrically connected to a battery outside the controller (1000); the capacitor assembly (40) further comprises a power distribution conductive bar (43), the power distribution conductive bar (43) is electrically connected to the DC power supply and / or the battery, and the power distribution conductive bar (43) is also electrically connected to the power supply assembly (400) of the controller (1000).

22. The controller (1000) according to claim 17, characterized in that The control component (300) of the controller (1000) further includes a power device module (70), and the capacitor component (40) is electrically connected to the power device module (70).

23. The controller (1000) according to claim 22, characterized in that The capacitor assembly (40) and the power device module (70) are connected by laser welding.

24. The controller (1000) according to claim 16, characterized in that The control component (300) of the controller (1000) further comprises a DC charging filter (80); the relay (600) is arranged on the DC charging filter (80); and the DC charging filter (80) is used to be electrically connected to an external DC power supply of the controller (1000).

25. The controller (1000) according to claim 24, characterized in that A charging circuit and a boost circuit are formed; at least parts of the charging circuit and the boost circuit are arranged on the DC charging filter (80); two relays (600) are arranged on the DC charging filter (80); and the two relays (600) are respectively connected to the charging circuit and the boost circuit.

26. The controller (1000) according to claim 1, characterized in that The control component (300) of the controller (1000) comprises a three-phase conductive bar component (50); the three-phase conductive bar component (50) is used to be electrically connected to a power device module (70) of the control component (300); the three-phase conductive bar component (50) comprises a second shell (51), a U-phase conductive bar (52), a V-phase conductive bar (53), a W-phase conductive bar (54) and a first filtering magnetic ring (55); the second shell (51), the U-phase conductive bar (52), the V-phase conductive bar (53), the W-phase conductive bar (54) and the first filtering magnetic ring (55) are integrally injection molded.

27. The controller (1000) according to claim 1, characterized in that The control component (300) of the controller (1000) comprises a DC bus filter (60); the DC bus filter (60) is used to be electrically connected to the capacitor component (40) of the control component (300); the DC bus filter (60) comprises an X capacitor (61), a Y capacitor (62) and a second filtering magnetic ring (63); the X capacitor (61), the Y capacitor (62) and the second filtering magnetic ring (63) are all used to filter a circuit connected to the DC bus filter (60).

28. An electric assembly (10000), characterized in that: A controller (1000) comprising any one of claims 1-27.

29. The electric assembly (10000) according to claim 28, characterized in that: The housing (10) further comprises a motor (3000) and a reducer (2000) connected thereto; the housing (10) further comprises a partition wall (16) connected to the side wall (11); the partition wall (16) is used to separate the first accommodating chamber (14) from the second accommodating chamber (15); the side wall (11) comprises a first side wall (12) and a second side wall (13); the first side wall (12) and the partition wall (16) are used to form the first accommodating chamber (14); the second side wall (13) and the partition wall (16) are used to form the second accommodating chamber (15) ; The partition wall (16) is connected to the motor (3000) and the reducer (2000); the first side wall (12) is arranged on the side of the partition wall (16) facing away from the motor (3000); the second side wall (13) is arranged on the side of the partition wall (16) facing the motor (3000) and is located in the space enclosed by the motor (3000) and the reducer (2000); the controller (1000) further includes a power supply assembly (400), and the power supply assembly (400) is arranged in the second accommodating cavity (15).

30. The electric assembly (10000) according to claim 29, characterized in that: The motor (3000) comprises a first housing and a rotor, the reducer (2000) comprises a second housing and a reduction mechanism, the rotor is arranged in the first housing, and the reduction mechanism is arranged in the second housing; the first housing, the second housing and the housing (10) are integrally formed.

31. A vehicle, characterized in that: It comprises the controller (1000) described in any one of claims 1 to 27 or the electric assembly (10000) described in any one of claims 28 to 30.

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