BSG motor, inverter of BSG motor, heat dissipation plate, cooling pipeline and manufacturing method of BSG motor

Abstract

The invention discloses a BSG motor and an inverter, a heat dissipation plate and a cooling pipeline thereof and a manufacturing method, the BSG motor comprises the inverter, the inverter comprises the heat dissipation plate, the heat dissipation plate comprises a plate body and the cooling pipeline arranged in the plate body, the cooling pipeline comprises a hollow metal pipeline body, and the metal pipeline body is arranged in the plate body. A cooling liquid inlet and a cooling liquid outlet are formed in the two ends of the metal pipeline body respectively, a plurality of heat dissipation grids are arranged on the inner wall of the metal pipeline body, and the heat dissipation grids are evenly distributed on the inner wall of the metal pipeline body in the circumferential direction with the axis of the metal pipeline body as the original point. The multiple heat dissipation grids extend to the positions close to the cooling liquid inlet and the cooling liquid outlet in the length direction of the metal pipeline body. The invention further provides a manufacturing method of the cooling pipeline. According to the cooling pipeline, the heat exchange area is increased, the process cost is reduced, the cooling pipeline can be directly pre-buried into the heat dissipation plate body, one-time forming is achieved, and the machining cost and material waste of the heat dissipation plate are reduced.

Description

Technical Field

[0001] The present invention relates to a BSG liquid-cooled motor, in particular to a BSG motor, its inverter, heat dissipation plate, cooling pipe and manufacturing method. Background Art

[0002] For the heat dissipation plate of the inverter of the existing BSG (belt-driven starter generator) motor, the bottom plate is formed by a mold, the cover plate is formed by stamping, and the bottom plate and the cover plate are connected by friction stir welding process. This structure has the following problems or defects:

[0003] 1) The U-shaped flow channel groove structure of the heat dissipation plate bottom plate is complex, difficult to form by mold, and the mold cost is high;

[0004] 2) The friction stir welding process has a high cost;

[0005] 3) When welding, the periphery of the cover plate is heated and melted, and the center sinks. A large machining allowance needs to be reserved on the upper end surface of the heat dissipation plate, increasing the machining cost and material waste. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to provide a BSG motor, its inverter, heat dissipation plate, cooling pipe and manufacturing method in view of the above defects of the prior art.

[0007] To achieve the above object, the present invention provides a cooling pipe, which includes a hollow metal pipe body. The two ends of the metal pipe body are respectively set as a coolant inlet and a coolant outlet. A plurality of heat dissipation grids are arranged on the inner wall of the metal pipe body, and the plurality of heat dissipation grids are circumferentially evenly distributed on the inner wall of the metal pipe body with the axis of the metal pipe body as the origin; the plurality of heat dissipation grids extend along the length direction of the metal pipe body to approach the coolant inlet and the coolant outlet.

[0008] For the above cooling pipe, the metal pipe body is a copper pipe or an aluminum pipe.

[0009] For the above cooling pipe, the metal pipe body is a cold-drawn or extruded forming part.

[0010] For the above cooling pipe, the metal pipe body is bent into a U-shaped pipe, an annular pipe or a spiral pipe.

[0011] For the above cooling pipe, the ratio of the inner circumference to the outer circumference of the metal pipe body is 1.3 - 3.3:1.

[0012] To better achieve the above object, the present invention also provides a manufacturing method of a cooling pipe, which is used for the processing of the above cooling pipe and includes the following steps:

[0013] S100, using a cooling pipe mold to cold-draw or extrude a copper material or an aluminum material into a metal pipe body having a plurality of heat dissipation grids uniformly distributed along the circumferential direction on the inner wall;

[0014] S200, milling off 20-25 mm of the heat dissipation grilles at both ends of the metal pipe body; and

[0015] S300, bending the two ends of the milled heat sink to serve as a coolant inlet and a coolant outlet respectively.

[0016] The manufacturing method of the cooling pipe further comprises:

[0017] S400, bending the metal pipe body into a U-shaped pipe, a ring pipe or a spiral pipe as required.

[0018] The above-mentioned manufacturing method of the cooling pipe, wherein the cooling pipe mold includes a shell, a piston and a core shaft, the core shaft is installed on the piston, the piston is installed in the shell, and together with the shell, encloses a cavity for accommodating the copper material or the aluminum material, and the piston moves along the core shaft in the cavity; a metal outlet is provided at the center of the end face of the shell adjacent to the cavity, the core shaft is inserted into the metal outlet, and a grid structure adapted to the heat sink is provided at the connecting end of the core shaft and the metal outlet.

[0019] In order to better achieve the above-mentioned purpose, the present invention also provides a heat dissipation plate of a BSG motor inverter, comprising a plate body and a cooling pipe arranged in the plate body, wherein the cooling pipe is the above-mentioned cooling pipe, the cooling pipe is a U-shaped pipe, and is pre-buried in the plate body and formed in one step.

[0020] In order to better achieve the above-mentioned purpose, the present invention also provides a BSG motor inverter, which includes the above-mentioned heat sink.

[0021] In order to better achieve the above-mentioned purpose, the present invention also provides a BSG motor, which includes the above-mentioned BSG motor inverter.

[0022] The technical effects of the present invention are:

[0023] Compared with the U-shaped flow channel groove of the prior art, the heat dissipation plate of the present invention uses a cooling pipe with heat dissipation grids inside to achieve the heat dissipation function, increasing the heat exchange area; when casting the heat dissipation plate, the cooling pipe is pre-buried, and the mold can be formed in one time, without a cover plate and subsequent welding, reducing the process cost; the heat dissipation grids inside the cooling pipe can be adjusted according to the actual heat dissipation requirements. The casting mold of the heat dissipation plate is simple and low in cost, and the cooling pipe can be directly cast into the aluminum plate; the casting is formed in one time, without making a cover plate, saving the cost of friction stir welding, and the problem of the cover plate sinking caused by welding is also solved, reducing the machining cost and material waste.

[0024] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments, but it is not limited to the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 Schematic diagram of the cooling pipe structure according to an embodiment of the present invention;

[0026] Figure 2 For Figure 1 A-A cross-sectional view of;

[0027] Figure 3 Schematic diagram of the internal fluid structure of the cooling pipe according to another embodiment of the present invention;

[0028] Figure 4 Optimal heat dissipation ratio fitting diagram of the cooling pipe according to an embodiment of the present invention;

[0029] Figure 5 Schematic diagram of the cooling pipe mold structure according to an embodiment of the present invention;

[0030] Figure 6 Schematic diagram of the heat dissipation plate structure according to an embodiment of the present invention;

[0031] Figure 7 Comparison of the maximum temperature rise of MOS with different heat dissipation structures according to an embodiment of the present invention;

[0032] Figure 8 Comparison of the water flow rate with different heat dissipation structures according to an embodiment of the present invention;

[0033] Figure 9 Schematic diagram of the BSG motor inverter structure according to an embodiment of the present invention.

[0034] Among them, the reference numerals

[0035] 1 BSG motor inverter

[0036] 11 DBC component

[0037] 2 Heat dissipation plate

[0038] 21 Plate body

[0039] 3 Cooling pipes

[0040] 31 Metal pipe body

[0041] 32 Heat dissipation grids

[0042] 33 Coolant inlet

[0043] 34 Coolant outlet

[0044] 4 Cooling pipe mold

[0045] 41 Housing

[0046] 42 Piston

[0047] 43 Mandrel

[0048] 44 Cavity

[0049] 45 Grid

[0050] 46 Metal outlet Specific implementation manners

[0051] The structural principle and working principle of the present invention will be specifically described below in conjunction with the accompanying drawings:

[0052] See Figure 1 and Figure 2 , Figure 1 is a schematic structural diagram of the cooling pipe 3 of an embodiment of the present invention, Figure 2 is Figure 1 The A-A sectional view of. The cooling pipe 3 of the present invention includes a hollow metal pipe body 31. The two ends of the metal pipe body 31 are respectively provided with a coolant inlet 33 and a coolant outlet 34. A plurality of heat dissipation grids 32 are circumferentially and uniformly distributed on the inner wall of the metal pipe body 31, that is, a plurality of the heat dissipation grids 32 are circumferentially and uniformly distributed on the inner wall of the metal pipe body 31 with the axis of the metal pipe body 31 as the origin. The extension lines of the side lines of the heat dissipation grids 32 in the same cross section pass through the center of the metal pipe body 31; a plurality of the heat dissipation grids 32 extend along the length direction of the metal pipe body 31 to be close to the coolant inlet 33 and the coolant outlet 34. Among them, the metal pipe body 31 is preferably a copper pipe or an aluminum pipe, and can also be other metal materials with good thermal conductivity and plasticity. The metal pipe body 31 is preferably a cold-drawn or extruded forming part.

[0053] See Figure 3 , Figure 3 is a schematic diagram of the internal fluid structure of the cooling pipe 3 of another embodiment of the present invention. The metal pipe body 31 of this embodiment can be bent into a U-shaped pipe, an annular pipe or a spiral pipe according to the use needs. Figure 1 The U-shaped pipe structure shown is applicable to the heat dissipation plate 2 of the BSG motor inverter 1, Figure 3The shown spiral tube structure is applicable to the cooling pipe 3 of the BSG motor. For the water-cooled drive motor cooling pipe 3, annular or spiral pipes are used, and the heat dissipation grids 32 inside the pipes can increase the heat exchange area. It can also be bent into an annular pipe or other special-shaped pipes according to needs. For example, it can be used as the cooling pipe 3 of the EV controller, and the cooling pipe is set according to the positions of electrical components.

[0054] See Figure 4 , Figure 4 is the fitting diagram of the optimal heat dissipation ratio of the cooling pipe in an embodiment of the present invention. In this embodiment, the optimal ratio range of the inner circumferential length to the outer circumferential length of the metal pipe body of the cooling pipe is 1.3 - 3.3:1.

[0055] See Figure 5 , Figure 5 is the structural schematic diagram of the cooling pipe mold 4 in an embodiment of the present invention. The cooling pipe 3 adopts Figure 5 the shown cooling pipe mold 4, and is processed by the following manufacturing method, which specifically includes the following steps:

[0056] Step S100: Use the cooling pipe mold 4 to cold-draw or extrude metal materials such as copper, aluminum, or other metals with good thermal conductivity and plasticity into a metal pipe body 31 with a plurality of heat dissipation grids 32 evenly distributed along the circumference on the inner wall;

[0057] Step S200: Milling off 20 - 25 mm of the heat dissipation grids 32 at both ends of the metal pipe body 31; and

[0058] Step S300: Bend both ends of the metal pipe body 31 from which the heat dissipation grids 32 are milled, and use them as the coolant inlet 33 and the coolant outlet 34 respectively.

[0059] It may also include:

[0060] Step S400: Bend the metal pipe body 31 into a U-shaped pipe, an annular pipe or a spiral pipe according to needs.

[0061] The cooling pipes of the present invention are processed using a special mold. In this embodiment, the cooling pipe mold 4 includes a housing 41, a piston 42, and a mandrel 43. The mandrel 43 is installed on the piston 42, and the piston 42 is installed inside the housing 41 and together with the housing 41 encloses a cavity 44 for accommodating the copper or aluminum material. The piston 42 moves along the mandrel 43 inside the cavity 44. At the center of the end face of the housing 41 adjacent to the cavity 44, there is a metal outlet 46. The mandrel 43 passes through the metal outlet 46, and at the connection end of the mandrel 43 and the metal outlet 46, there is a grid 45 adapted to the heat dissipation grid 32. That is, the grids 45 are evenly distributed circumferentially on the outer wall of the mandrel 43, and the grids 45 are parallel to each other and also parallel to the axis of the mandrel 43. The number and size parameters of the grids 45 are all adapted to the heat dissipation grids 32 of the corresponding cooling pipe 3 to be processed.

[0062] See Figure 6 , Figure 6 is a schematic structural diagram of the heat dissipation plate 2 of an embodiment of the present invention. The heat dissipation plate 2 of the BSG motor inverter 1 of the present invention includes a plate body 21 and cooling pipes 3 arranged inside the plate body 21. Among them, the cooling pipes 3 are U-shaped pipes as shown in Figure 1 and are pre-buried in the plate body 21 for one-time molding. There are no heat dissipation grids 32 at the coolant inlet 33 and coolant outlet 34 of the cooling pipes, which is convenient for cooling water to enter the cooling pipes. Moreover, the bending radii at the coolant inlet 33 and coolant outlet 34 are small, and not setting the heat dissipation grids 32 can make the bending forming simpler.

[0063] In this embodiment, the metal pipe body 31 of the cooling pipe 3 is made of copper pipe, and the inner diameter is preferably the wall thickness is preferably 1 mm, and 36 heat dissipation grids 32 with a height of 1.5 mm are preferably evenly distributed on the inner wall of the copper pipe. The copper pipe is cast in the heat dissipation plate 2, and the thickness of the heat dissipation plate 2 is preferably 14.5 mm. The copper pipe can be formed by cold drawing or extrusion. After the straight pipe is formed, it is bent into a U-shaped pipe. The heat dissipation grids 32 on the inner walls of both ends of the copper pipe are milled off by 20 - 25 mm, and then both ends are bent into the coolant inlet 33 and coolant outlet 34. The heat dissipation plate 2 can pre-bury the copper pipe during the casting and forming process.

[0064] See Figure 7 and Figure 8 , Figure 7 is a comparison of the maximum temperature rise of MOS (metal-oxide-semiconductor field effect transistor) between an embodiment of the present invention and different heat dissipation structures. Figure 8The water flow rate of an embodiment of the present invention is compared with different heat dissipation structures. In the figure, A is a U-shaped flow channel groove of the existing structure, with a heat dissipation column inside, which requires a cover plate + stir friction welding seal; B is based on structure A without the heat dissipation column; C is a U-shaped thick copper tube, the upper surface of the copper tube is flattened, and the inlet and outlet are connected with thin copper tubes; D is a cooling water channel composed of only one copper tube; E is the cooling water channel structure of the present invention. As can be seen from the figure, for the cooling water flow rate, the existing structure A is the worst, and the cooling pipe 3 of the present invention is obviously better than the existing structure.

[0065] Compared with the U-shaped flow channel in the prior art, its bottom plate is cast, the U-shaped flow channel structure is complex, and the mold cost is high; the bottom of the flow channel is thin-walled, and the water plate is easy to deform during mold forming; to solve this problem, the thickness of the mold parts is thickened, which increases material waste; the bottom plate has a complex structure, and there are many pore defects after forming, and the yield is low; the cover plate is stamped, and in order to ensure the processing allowance, a thicker aluminum plate needs to be used; the bottom plate and the cover plate are stir-friction welded, and the welding cost is high. During welding, the cover plate melts all around and sinks in the center. A large processing allowance needs to be reserved for the bottom plate and the cover plate, and the machining cost is high; when the cover plate and the bottom plate are nickel-plated on the water plate, the pore defects affect the coating quality and the finished product yield is low. The heat sink 2 of the present invention uses a cooling pipe with a heat sink grid 32 inside to achieve the heat dissipation function, which increases the heat exchange area; the copper tube or aluminum tube is cold-drawn or extruded using a special cooling pipe mold, and can be flexibly bent as needed; the cooling pipe is pre-buried when the heat sink 2 is cast, and can be directly cast; there is no complex internal structure, the mold is simple, and the design and manufacturing cost is low; there is no thin wall, which solves the problem of water plate deformation and reduces the thickness of the mold; the water plate has a simple structure and can significantly reduce the number of pore defects; the mold can be formed in one time, without a cover plate and subsequent welding, which reduces the thickness of the mold and reduces the machining cost; at the same time, the pore defects are reduced and the yield is improved; and the heat sink 32 inside the cooling pipe can adjust the structure according to the actual heat dissipation needs. In summary, the casting mold of the heat sink 2 is simple and low in cost, and the cooling pipe can be directly cast into the aluminum plate; the casting is formed in one time, and there is no need to make a cover plate, which saves the cost of stir friction welding, and the problem of sinking of the cover plate caused by welding is also solved, reducing the machining cost and material waste. At the same time, the cooling pipe with the heat dissipation grid 32 of the present invention has a larger total flow rate and the same heat dissipation capacity at the same water pressure than the U-shaped flow channel groove with irregularly distributed heat dissipation columns in the prior art.

[0066] See also Figure 9 , Figure 9 FIG. 1 is a schematic diagram of the structure of a BSG motor inverter 1 according to an embodiment of the present invention. The BSG motor inverter 1 of the present invention can be used as follows: Figure 5The heat dissipation plate 2 shown, and multiple DBC (direct bond copper, which is a lower-level component of the power module) components 11 of the BSG motor inverter 1 can preferably be welded on the heat dissipation plate 2 using SAC305 soldering sheets. The BSG motor inverter 1 of the present invention can be used for any model of BSG motor, and the BSG motor can be mainly applied to commercial vehicles. Since the composition, structure, mutual positional relationship, connection relationship, and functions of other parts of the BSG motor and the BSG motor inverter 1 are all relatively mature prior arts, they will not be elaborated herein.

[0067] Of course, the present invention can also have many other embodiments. Without departing from the spirit and essence of the present invention, those skilled in the art can make various corresponding changes and deformations according to the present invention, but these corresponding changes and deformations should all fall within the protection scope of the appended claims of the present invention.

Claims

1. A cooling pipe, characterized in that, it includes a hollow metal pipe body, both ends of the metal pipe body are respectively set as a coolant inlet and a coolant outlet, and a plurality of heat dissipation grids are arranged on the inner wall of the metal pipe body, and the plurality of heat dissipation grids are circumferentially evenly distributed on the inner wall of the metal pipe body with the axis of the metal pipe body as the origin; the plurality of heat dissipation grids extend along the length direction of the metal pipe body to be close to the coolant inlet and the coolant outlet.

2. The cooling pipe according to claim 1, characterized in that, the metal pipe body is a copper pipe or an aluminum pipe.

3. The cooling pipe according to claim 1 or 2, characterized in that, the metal pipe body is a cold-drawn or extruded forming part.

4. The cooling pipe according to claim 1, characterized in that, the metal pipe body is bent into a U-shaped pipe, an annular pipe or a spiral pipe.

5. The cooling pipe according to claim 1, characterized in that, the ratio of the inner circle circumference to the outer circle circumference of the metal pipe body is 1.3 - 3.3:

1.

6. A manufacturing method of a cooling pipe, characterized in that, it is used for processing the cooling pipe according to any one of claims 1 - 5, and includes the following steps: S100. Cold-draw or extrude copper or aluminum into a metal pipe body with a plurality of heat dissipation grids circumferentially evenly distributed on the inner wall by using a cooling pipe mold; S200. Milling off 20 - 25 mm of the heat dissipation grids at both ends of the metal pipe body; and S300. Bending the two ends where the heat dissipation grids are milled off to be used as the coolant inlet and the coolant outlet respectively.

7. The manufacturing method of the cooling pipe according to claim 6, characterized in that, it further includes: S400. Bending the metal pipe body into a U-shaped pipe, an annular pipe or a spiral pipe as needed.

8. The manufacturing method of the cooling pipe according to claim 6 or 7, characterized in that, the cooling pipe mold includes a shell, a piston and a mandrel, the mandrel is installed on the piston, the piston is installed in the shell, and together with the shell encloses a cavity for accommodating the copper or aluminum, and the piston moves along the mandrel in the cavity; a metal outlet is arranged at the center of the end face of the shell adjacent to the cavity, the mandrel passes through the metal outlet, and a grid structure adapted to the heat dissipation grid is arranged at the connection end of the mandrel and the metal outlet.

9. A heat dissipation plate of a BSG motor inverter, including a plate body and a cooling pipe arranged in the plate body, characterized in that, the cooling pipe is the cooling pipe according to any one of claims 1 - 5, the cooling pipe is a U-shaped pipe and is pre-buried in the plate body for one-time molding.

10. A BSG motor inverter, characterized in that, it includes the heat dissipation plate according to claim 9.

11. A BSG motor, characterized in that, it includes the BSG motor inverter according to claim 10.

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