Motor control device and power assembly

Abstract

The invention relates to the technical field of electrical equipment, and provides a motor control device and a power assembly.The motor control device comprises a first module set and a second module set; the first module group comprises a capacitor module and a filtering module, and the capacitor module is arranged on one side of the filtering module along a first direction; the second module group comprises a power module, the second module group is arranged on one side of the first module group along a second direction, and an included angle is formed between the first direction and the second direction. By improving the structure of the motor control device, the integration degree of the motor control device, the motor, the speed reducer and other parts is better, the space utilization rate is higher, and the space requirement of the whole vehicle for the all-in-one electric drive system is met.

Description

Technical Field

[0001] The present invention relates to the technical field of electrical equipment, and in particular to a motor control device and a power assembly. Background Art

[0002] With the rapid development of the new energy vehicle industry, the entire vehicle has also put forward requirements for high voltage, integration, and intelligence for the electric drive assembly. Among them, integration requires the electric vehicle power system to be more compact, lighter, and more flexible.

[0003] The highly integrated powertrain system of an electric vehicle typically consists of a motor, a speed reducer, and a motor controller. The motor controller converts the DC power from the vehicle's high-voltage battery into high-voltage AC power, driving the motor in the desired mode. As the control center of the powertrain, the integrated design of the motor controller is crucial to the functionality, quality, and cost of the electric drive axle assembly.

[0004] Existing motor controllers typically utilize a brick-like structure, also known as an inverter brick. This structure integrates the power module, cooling structure, and capacitors into a rectangular brick-like structure. This motor controller focuses on its own integration, but within the entire power system, the motor controller also needs to be integrated with other components, such as the motor and reducer. Due to its brick-like structure, the motor controller's shape is difficult to match with the motor and reducer, resulting in insufficient integration between the motor controller, the motor, and the reducer, and ultimately, insufficient integration of the power system.

[0005] In existing vehicles, the highly integrated all-in-one electric drive system has more stringent space requirements. Therefore, improving the integration of motor control devices with components such as motors and reducers is a technical problem that needs to be solved urgently in this field. To this end, the present invention provides a motor control device and a powertrain. Summary of the Invention

[0006] The purpose of the present invention is to provide a motor control device and a powertrain. By improving the structure of the motor control device, the motor control device is better integrated with components such as the motor and the reducer, and the space utilization is higher, thereby meeting the space requirements of the vehicle for the all-in-one electric drive system.

[0007] The present invention provides a motor control device, comprising a first module group and a second module group;

[0008] The first module group includes a capacitor module and a filter module, and the capacitor module is arranged on one side of the filter module along the first direction;

[0009] The second module group includes a power module. The second module group is arranged on one side of the first module group along a second direction, and the first direction and the second direction are arranged at an angle.

[0010] Optionally, the first direction and the second direction are perpendicular.

[0011] Optionally, the motor control device further includes a shell, the shell is divided into at least a first chamber and a second chamber along the first direction, the capacitor module is arranged in the first chamber, and the filter module is arranged in the second chamber.

[0012] Optionally, the motor control device further includes a first connector, one end of which is located in the first cavity and electrically connected to the capacitor module, and the other end of the first connector passes through the first cavity to the second cavity and is electrically connected to the filter module.

[0013] Optionally, the motor control device further includes a partition, which is arranged between the first chamber and the second chamber, and a through groove communicating with the first chamber and the second chamber is formed on the partition, and the first connecting member is sealed and passes through the through groove.

[0014] Optionally, the motor control device further includes a sealing cover plate, which is sealed to cover the through groove.

[0015] Optionally, a through hole for the first connector to pass through is formed on the sealing cover plate, and the first connector and the inner wall of the through hole are sealed by a sealing member, or the sealing cover plate and the first connector are integrally injection molded.

[0016] Optionally, the motor control device further includes a filter input terminal, the filter input terminal is located on one side of the housing along the third direction, and the filter input terminal is electrically connected to the filter module;

[0017] The third direction is perpendicular to the first direction and the second direction.

[0018] Optionally, along the third direction, the filter input terminal is arranged opposite to the second cavity.

[0019] Optionally, the second module group further includes a heat exchange module, and the power module is arranged in the heat exchange module.

[0020] Optionally, the power module is welded to the heat exchange module by vacuum vapor welding.

[0021] Optionally, the heat exchange module is a water-cooling plate, the water-cooling plate is perpendicular to the first direction, and the power module is arranged on one side of the water-cooling plate along the first direction.

[0022] Optionally, the second module group further includes a first circuit board and a second circuit board, and the first circuit board and the second circuit board are respectively located on two sides of the heat exchange module along the first direction.

[0023] Optionally, when the motor control device includes a shell, the shell includes a shell body and a substrate, the first chamber and the second chamber are located in the shell body, the substrate is connected to one side of the shell body along the second direction, and the heat exchange module is arranged on the substrate.

[0024] Optionally, the power module, the heat exchange module and the first circuit board are arranged on one side of the substrate along the first direction, and the second circuit board is arranged on the other side of the substrate along the first direction.

[0025] The present invention also provides a powertrain, which includes the motor control device described above.

[0026] To summarize, the motor control device includes a first module group and a second module group; the first module group includes a capacitor module and a filter module, and the capacitor module is arranged on one side of the filter module along the first direction; the second module group includes a power module, and the second module group is arranged on one side of the first module group along the second direction, and the first direction and the second direction are arranged at an angle.

[0027] With this configuration, the motor control device integrates the filter module and capacitor module along a first direction. The filter module is located to one side of the capacitor module along the first direction. This helps fully utilize the space below the motor or reducer in common three-in-one and multi-in-one electric drive systems, improving space utilization. Furthermore, the integration of the filter module and capacitor module utilizes space in the vertical direction, helping to reduce the additional connection area between the two and avoiding the space waste and structural complexity caused by excessive fixings or connectors.

[0028] The arrangement of the motor control device described above helps to significantly reduce the planar size of the motor control device, enabling the three-in-one or multi-in-one electric drive system to achieve more functional integration within a limited space, further improving its integration level.

[0029] The motor control device described above helps to reduce the length of the connecting copper bars between the capacitor module and the filter module and between the capacitor module and the power module through integration, thereby reducing material costs and connection losses.

[0030] The EMC (electromagnetic compatibility) performance of the above-mentioned motor control device is greatly improved. This arrangement allows the capacitor module and the filter module to be closer to noise sources such as power devices, more effectively filtering out high-frequency noise in the circuit of the motor control device and improving the filtering effect. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1This is a schematic diagram of the layout structure of existing inverter bricks;

[0032] Figure 2 Schematic diagram of the arrangement of a motor control device according to an embodiment of the present invention;

[0033] Figure 3 is a schematic cross-sectional structural diagram of a housing according to an embodiment of the present invention;

[0034] Figure 4 A schematic diagram of the internal structure of a housing according to an embodiment of the present invention;

[0035] Figure 5 is a schematic diagram of the overall structure of a motor control device according to an embodiment of the present invention;

[0036] Figure 6 Schematic diagram of the partial structure of a motor control device according to an embodiment of the present invention Figure 1 ;

[0037] Figure 7 Schematic diagram of the partial structure of a motor control device according to an embodiment of the present invention Figure 2 ;

[0038] Figure 8 Schematic diagram of the partial structure of a motor control device according to an embodiment of the present invention Figure 3 .

[0039] Among them, in the accompanying drawings:

[0040] 100-motor; 200-reducer; 300-inverter brick; 400-first special-shaped area; 500-second special-shaped area;

[0041] 10-first module group; 11-capacitor module; 12-filter module;

[0042] 20 - second module group; 21 - power module; 22 - heat exchange module; 23 - copper busbar bracket; 24 - first circuit board; 25 - second circuit board;

[0043] 30-housing; 301-housing body; 302-base plate; 303-partition plate; 304-through groove; 305-sealing cover plate; 306-top cover plate; 307-first opening; 308-second opening; 309-connecting structure;

[0044] 31-first chamber; 32-second chamber;

[0045] 40-first connecting member;

[0046] 50- filter input terminal;

[0047] a-first direction; b-second direction; c-third direction. DETAILED DESCRIPTION

[0048] The following is a detailed description of the motor control device and powertrain according to the present invention, with reference to the accompanying drawings and specific embodiments. The advantages and features of the present invention will become more apparent from the following description. It should be noted that the accompanying drawings are highly simplified and not to exact scale, and are intended solely to facilitate and clearly illustrate the embodiments of the present invention.

[0049] As used in the present invention, the singular forms "a", "an", and "the" include plural referents. The term "or" is generally used to include the meaning of "and / or", the term "several" is generally used to include the meaning of "at least one", and the terms "at least two" or "a plurality" are generally used to include the meaning of "two or more". In addition, the terms "first", "second", and "third" are used for descriptive purposes only and should not be understood to indicate or imply relative importance or implicitly specify the number of the technical features indicated. Therefore, features specified as "first", "second", and "third" may explicitly or implicitly include one or at least two of the features. In addition, as used in the present invention, "mounted", "connected", "connected", and one element "disposed" on another element should be understood broadly and generally only indicate that there is a connection, coupling, mating, or transmission relationship between the two elements, and the connection, coupling, mating, or transmission between the two elements can be direct or indirect through an intermediate element. It should not be understood to indicate or imply a spatial positional relationship between the two elements, that is, one element can be in any orientation such as inside, outside, above, below, or to the side of another element, unless the content clearly indicates otherwise. For those skilled in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances. In addition, directional terms such as above, below, up, down, upward, downward, left, right, etc. are used with respect to the exemplary embodiments as they are shown in the figures, with the upward or upper direction being toward the top of the corresponding figure and the downward or lower direction being toward the bottom of the corresponding figure.

[0050] As the demand for high-level integration in electric vehicles continues to grow, all-in-one electric drive systems are becoming a major trend in this area. For example, a three-in-one electric drive system typically consists of a motor, a reducer, and a motor controller.

[0051] Existing motor controllers generally have a brick structure, also known as an inverter brick structure, that is, they integrate a power module, a cooling structure, and a capacitor to form an overall rectangular brick structure.

[0052] Combine Figure 1As shown in FIG, a layout of a three-in-one electric drive system is shown, wherein the motor 100 and the reducer 200 are arranged in parallel, and the inverter brick 300 is arranged in parallel with the motor 100 and the reducer 200. Figure 1 As shown, there are multiple irregularly shaped spaces within the envelope, such as a first irregularly shaped region 400 between the inverter brick 300 and the reducer 200, and a second irregularly shaped region 500 between the inverter brick 300 and the motor 100. Since the inverter brick 300 is a roughly regular rectangular parallelepiped, these irregularly shaped regions are difficult to utilize, resulting in insufficient integration of the entire power system and low space utilization.

[0053] In the above example, the motor 100 and the reducer 200 are arranged in parallel. When the motor 100 and the reducer 200 are arranged coaxially, the corresponding irregularly shaped area cannot be effectively utilized.

[0054] The above example provides a three-in-one electric drive system to illustrate space utilization. In a more integrated all-in-one electric bridge (such as four-in-one, five-in-one, etc.), core components such as motors, reducers, motor controllers, on-board chargers (OBCs), DCDC converters, and power distribution units (PDUs) are usually included. Compared with three-in-one electric bridges, more space is required, so the space requirements for all-in-one electric bridges are more stringent for the whole vehicle. All-in-one electric drive systems usually use a common shell integration, which further leads to many special-shaped spaces being unusable and the available space for the motor controller cannot be further expanded, which greatly limits its promotion and use in high-power application scenarios. In addition, the filter module in the all-in-one electric drive system is usually set independently, resulting in a lot of space wasted in the connection area between the filter module and other components, and a separate fixed assembly space is required, which is not conducive to highly integrated design.

[0055] Based on this, the present invention provides a motor control device, including a first module group 10 and a second module group 20;

[0056] The first module group 10 includes a capacitor module 11 and a filter module 12, wherein the capacitor module 11 is disposed on one side of the filter module 12 along the first direction a;

[0057] The second module group 20 includes a power module 21 . The second module group 20 is disposed on one side of the first module group 10 along a second direction b. The first direction a and the second direction b form an angle.

[0058] In this embodiment, the power module 21 includes but is not limited to a PM6 module, an HPD module, etc. The specific model of the power module 21 can be selected based on actual usage requirements.

[0059] In this embodiment, the capacitor module 11 is assembled by a capacitor core, a copper busbar, and insulating paper. The output copper busbar of the capacitor module 11 is electrically connected to the input end of the power module 21, and can also be electrically connected to the input end of the power module 21 through a transfer copper busbar.

[0060] In this embodiment, the filter module 12 is assembled from an X capacitor, a Y capacitor, a magnetic core, and a copper busbar. The filter module 12 is externally connected to a battery and is electrically connected to the capacitor module 11 .

[0061] Combine Figure 2 As shown, in this embodiment, the first direction a and the second direction b are perpendicular. In this arrangement, the capacitor module 11 and the filter module 12 are arranged along the first direction a, which is conducive to utilizing the special-shaped space in the electric drive system, such as using Figure 2 Furthermore, the arrangement of the first module group 10 and the second module group 20 along the second direction b, combined with the arrangement of the capacitor module 11 and the filter module 12, helps reduce the size of the entire motor control device along the second direction b, thereby reducing the space occupied along this direction.

[0062] The motor control device described above integrates the filter module 12 and the capacitor module 11 along the first direction a. The filter module 12 is located on one side of the capacitor module 11 along the first direction a. This helps to fully utilize the space below the motor or reducer in common three-in-one and multi-in-one electric drive systems, thereby improving space utilization. At the same time, the integration of the filter module 12 and the capacitor module 11 utilizes the space in the height direction, helps to reduce the additional connection area between the two, and avoids the space waste and structural complexity caused by excessive fixings or connectors.

[0063] The arrangement of the motor control device described above helps to significantly reduce the planar size of the motor control device, enabling the three-in-one or multi-in-one electric drive system to achieve more functional integration within a limited space, further improving its integration level.

[0064] The above motor control device helps to reduce the length of the connecting copper bars between the capacitor module 11 and the filter module 12 and between the capacitor module 11 and the power module 21 in an integrated manner, thereby reducing material costs and connection losses.

[0065] The EMC (electromagnetic compatibility) performance of the above-mentioned motor control device is greatly improved. This arrangement enables the capacitor module 11 and the filter module 12 to be closer to noise sources such as power devices, more effectively filtering out high-frequency noise in the circuit of the motor control device and improving the filtering effect.

[0066] In the above embodiment, the first direction a and the second direction b are perpendicular, meaning that the first module group 10 and the second module group 20 are arranged perpendicular to each other. In alternative embodiments, the angle between the first direction a and the second direction b can be adjusted based on actual space utilization requirements. This angle can be adjusted to the actual space being utilized, so that a portion of the first module group 10 and the second module group 20 can be accommodated within the desired irregularly shaped space.

[0067] For further information, please refer to Figures 3 to 5 As shown, the motor control device further includes a housing 30 , which is divided into a first chamber 31 and a second chamber 32 along the first direction a, wherein the capacitor module 11 is disposed in the first chamber 31 , and the filter module 12 is disposed in the second chamber 32 .

[0068] The motor control device also includes a first connector 40, one end of which is located in the first cavity 31 and electrically connected to the capacitor module 11, and the other end of the first connector 40 passes through the first cavity 31 to the second cavity 32 and is electrically connected to the capacitor module 11.

[0069] In the above arrangement, the first connecting member 40 is located inside the shell 30, and the first connecting member 40 does not pass through the shell 30, so that the electrical connection line between the capacitor module 11 and the filter module 12 is the shortest. On the one hand, the electrical connection line between the capacitor module 11 and the filter module 12 is reduced, reducing material costs and connection losses. On the other hand, it can reduce the space occupied by the connection line between the two, so that the electrical connection structure is integrated inside the shell 30, thereby improving the integration.

[0070] Please continue to refer to Figure 4 and Figure 5 As shown, the housing 30 includes a housing body 301 and a substrate 302 . The first chamber 31 and the second chamber 32 are located in the housing body 301 . The substrate 302 is connected to one side of the housing body 301 along the second direction b.

[0071] The housing body 301 serves as a mounting base for the capacitor module 11 and the filter module 12 , and the substrate 302 serves as a mounting base for the power module 21 .

[0072] The housing body 301 and the base plate 302 are preferably formed integrally, and the housing 30 can be made by a die-casting process. The housing 30 is made of metal, including but not limited to die-cast aluminum alloy, magnesium alloy, etc.

[0073] Combine Figures 3 to 5 As shown, a partition 303 is provided inside the housing body 301 , and the partition 303 is integrally formed with the housing body 301 . Figure 3 In the embodiment, the area inside the housing body 301 above the partition 303 serves as the first chamber 31, and the area inside the housing body 301 below the partition 303 serves as the second chamber 32. A through slot 304 is formed on the partition 303, and the first connecting member 40 passes through the through slot 304 in a sealed manner.

[0074] In this embodiment, the through groove 304 is sealed with a sealing cover plate 305 to seal the first connector 40 and the through groove 304 . The sealing cover plate 305 is bonded to the partition plate 303 . The sealing cover plate 305 is preferably made of insulating material, such as a plastic plate.

[0075] In this embodiment, the sealing cover plate 305 and the first connector 40 are integrally injection-molded. When the sealing cover plate 305 covers the through-slot 304, it seals the space between the first connector 40 and the through-slot 304. In alternative embodiments, the sealing cover plate 305 may have a through-hole for the first connector to pass through. The first connector and the inner wall of the through-hole are sealed by a sealing member, which may be a sealing ring or other sealing structure, such as sealant or sealing filler.

[0076] Combine Figure 4 As shown, in this embodiment, the base plate 302 and the partition plate 303 are integrally formed and are made of the same material as the housing body 301. In other alternative embodiments, the base plate 302 and the partition plate 303 may be formed as two separate plates.

[0077] Combine Figure 3 As shown, the first connecting member 40 is, for example, a capacitor input copper busbar. One end of the capacitor input copper busbar is located in the first chamber 31 and is connected to the input end of the capacitor module 11. The other end of the capacitor input copper busbar is sealed and passes through the through groove 304 to enter the second chamber 32 and is connected to the filter output copper busbar. The two copper buses can be electrically connected by laser welding or screws, and the filter output copper busbar is connected to the output end of the filter module 12.

[0078] In this embodiment, the partition 303 is connected to the housing body 301 by an integral molding method. In other alternative embodiments, the partition 303 and the housing body 301 can be connected by welding, mechanical connection, sealant bonding, etc.

[0079] After the capacitor module 11 is installed in the first chamber 31 , structural glue is poured into the first chamber 31 . After the filter module 12 is installed and accommodated in the second chamber 32 , structural glue is poured into the second chamber 32 , so that the capacitor module 11 and the filter module 12 are fixed inside the shell body 301 .

[0080] Please continue to refer to Figures 3 to 5As shown, the side plate of the housing body 301 away from the second chamber 32 along the first direction a serves as a top cover plate 306 . The top cover plate 306 is a detachable structure to facilitate the installation of the capacitor module 11 .

[0081] Please refer to Figure 5 As shown, the first chamber 31 has an opening on one side, along the second direction b, near the second module group 20. This opening is the first opening 307 of the housing body 301. The partition 303 and the base plate 302 are integrally formed and are essentially a single plate. A portion of the plate is located inside the housing body 301 as a partition, while the other portion extends outside the housing body 301 through the first opening 307 to serve as the base plate. The base plate serves as the mounting base for the power module 21.

[0082] The capacitor module 11 is fixed to the shell body 301 through a vacuum potting process. After the capacitor module 11 is installed in the first chamber 31 through the tooling and positioned relative to the shell body 301, a sealant is applied to the shell body 301, the top cover plate 306 is bonded, and a sealant is applied to the partition 303, and the sealing cover plate 305 is bonded. The output copper busbar of the capacitor module 11 extends from the first opening 307, and then the first chamber 31 is filled with glue through the first opening 307. After the glue solidifies, the capacitor module 11 and the shell body 301 form a whole, and the first opening 307 is now sealed by the glue. The output copper busbar extending from the capacitor module 11 is electrically connected to the DC input terminal of the power module 21, and can also be electrically connected to the input terminal of the power module 21 through a transfer copper busbar.

[0083] Combine Figures 5 to 8 As shown, a side of the second chamber 32 away from the first chamber 31 along the first direction a is open, and the opening serves as a second opening 308 of the housing body 301 .

[0084] The filter module 12 is fixed to the housing body 301 through a vacuum potting process. After the capacitor module 11 and the housing body 301 are potted, the filter module 12 is fixed by a tool in the second chamber 32 through the second opening 308, and the output copper bar of the filter module 12 is electrically connected to the first connector 40 (for example, the capacitor input copper bar). Then, the second chamber 32 is filled with glue through the second opening 308. After the glue solidifies, the filter module 12 and the housing body 301 form a whole. At this point, the second opening 308 is sealed by the colloid, and the housing body 301, the capacitor module 11 and the filter module 12 are connected into a whole.

[0085] Please continue to refer to Figure 5As shown, the motor control device further includes a filter input terminal 50, which is located on one side of the housing 30 along the third direction c. The filter input terminal 50 is electrically connected to the filter module 12 and is used to connect to an external battery. The third direction c is perpendicular to the first direction a and the second direction b.

[0086] The filter input terminal 50 serves as the input end of the filter input terminal 50. The filter input terminal 50 is, for example, a filter input copper bar. One end of the filter input terminal 50 is located in the second cavity 32 and connected to the input end of the filter module 12. The other end extends outside the housing body 301 through one side of the housing body 301 along the third direction c. Preferably, the filter input terminal 50 is located directly opposite the second cavity 32 along the third direction c.

[0087] This arrangement makes the filter input terminal 50 located at Figure 5 The overall lower position of the housing body 301 helps the filter input terminal 50 to be better arranged in the special-shaped space (for example, arranged in Figure 2 The special-shaped space above the middle reducer 200 is provided. This helps to further improve space utilization and enhance integration.

[0088] Please continue to refer to Figure 4 and Figure 5 As shown, in this embodiment, the housing body 301 is configured as a rectangular parallelepiped structure. The first direction a corresponds to the height direction of the housing body 301, the second direction b corresponds to the width direction of the housing body 301, and the third direction c corresponds to the length direction of the housing body 301. In other alternative embodiments, the housing body 301 can be adaptively adjusted based on the installation space requirements of the capacitor module 11 and the filter module 12 and the assembly relationship with other components. For example, the housing body 301 can be configured as a housing structure that is wide at the top and narrow at the bottom, approximately trapezoidal.

[0089] In this embodiment, a connecting structure 309 is connected to the outside of the housing body 301 . A connecting hole is provided on the connecting structure 309 . The connecting structure 309 facilitates the connection and fixation of the housing body 301 with the bridge housing or other components.

[0090] In this embodiment, the housing 30 is divided into two chambers along the first direction a. In other alternative embodiments, the housing 30 may be divided into more chambers along the first direction a, for example, three, four, or more chambers. The number of chambers may be adaptively adjusted based on integration requirements, and different modules may be placed in each chamber, allowing other modules to be integrated into the housing 30.

[0091] Furthermore, the second module group 20 further includes a heat exchange module 22 . The heat exchange module 22 is disposed on the substrate 302 , and the power module 21 is disposed on the heat exchange module 22 .

[0092] Combine Figure 5 and Figure 6 As shown, the heat exchange module 22 is a plate structure. Furthermore, the heat exchange module 22 is a water-cooled plate, which improves the heat dissipation efficiency of the power module 21 through water cooling. In other alternative embodiments, the heat exchange module 22 can be other forms of heat exchange structures, such as an immersion heat exchange structure, an air-cooled heat exchange structure, or other heat exchange structures.

[0093] In this embodiment, the water cooling plate (heat exchange module 22 ) is perpendicular to the first direction a, and is attached to the substrate 302 . The power module 21 is attached to one side of the water cooling plate along the first direction a.

[0094] The water-cooling plate adopts a closed cooling channel to avoid redundant sealing structures. The liquid inlet and outlet of the water-cooling plate are located below the water-cooling plate (on the side close to the base plate 302). Accordingly, an avoidance gap can be provided on the base plate 302 to avoid the liquid inlet and outlet of the water-cooling plate. This setting method is compatible with the water channel design of the existing electric drive axle on the one hand, and can also reduce the planar size of the entire motor control device on the other hand, which is conducive to the miniaturization design of the motor control device.

[0095] The power module 21 is a plate-type structure. As the primary heat-generating element of the motor control device, installing it close to the cooling channel of the heat exchange module 22 effectively ensures the heat dissipation efficiency of the power module 21. In this embodiment, a vacuum vapor phase welding process is used to weld the power module 21 to the cooling channel. This welding process achieves a tight connection between the power module 21 and the heat exchange module 22 under a vacuum environment, forming an atomic-level bond. This significantly reduces the contact thermal resistance, ensures that heat can be efficiently transferred from the power module 21 to the cooling channel of the heat exchange module 22, and improves the heat dissipation effect.

[0096] In other alternative embodiments, the power module 21 and the heat exchange module 22 may adopt other contact methods. In order to ensure that the cooling channels of the power module 21 and the heat exchange module 22 have lower interface thermal resistance, the following methods may also be adopted, including but not limited to:

[0097] Thermal interface material filling method: A thermal interface material, such as thermally conductive silicone, is placed between the cooling channels of the power module 21 and the heat exchange module 22. Thermally conductive silicone has excellent thermal conductivity and flexibility, and can fill the tiny gaps between the cooling channels of the power module 21 and the heat exchange module 22, effectively reducing the thermal resistance caused by the air gap. This enhances the efficiency of heat transfer from the power module 21 to the cooling channels of the heat exchange module 22, reducing the interface thermal resistance.

[0098] Other welding connection methods include the use of silver sintering. This process utilizes silver's high thermal conductivity and dense structure after sintering to form a good heat conduction path between the cooling channels of the power module 21 and the heat exchange module 22, reducing thermal resistance. It also offers high reliability and stability, making it suitable for connecting the cooling channels of the power module 21 and the heat exchange module 22 where heat dissipation requirements are high.

[0099] Immersion-based direct contact cooling: This method utilizes an immersion-based module cooling method, placing the power module 21 in direct contact with the coolant. This method eliminates the solid-solid interface thermal resistance found in traditional cooling methods, allowing the coolant to quickly remove heat generated by the power module 21. Through liquid convection and heat conduction, more efficient heat dissipation is achieved, further reducing interface thermal resistance and improving overall heat dissipation performance. This method is particularly suitable for cooling high-power-density power modules.

[0100] Combine Figure 7 As shown, in this embodiment, the output end of the power module 21 is electrically connected to the three-phase output copper busbar through the adapter copper busbar. The adapter copper busbar and the three-phase output copper busbar are welded and then integrally injection-molded into a copper busbar bracket 23. The copper busbar bracket 23 is provided on the power module 21.

[0101] In other alternative embodiments, the output end of the power module 21 may be directly electrically connected to the three-phase output copper busbar, and in this case, the copper busbar bracket 23 may not be provided.

[0102] Furthermore, the second module group 20 further includes a first circuit board 24 and a second circuit board 25, both of which are PCBs. The first circuit board 24 and the second circuit board 25 are respectively located on both sides of the heat exchange module 22 along the first direction a.

[0103] Specifically, the power module 21 , the heat exchange module 22 and the first circuit board 24 are arranged on one side of the substrate 302 along the first direction a, and the second circuit board 25 is arranged on the other side of the substrate 302 along the first direction a.

[0104] Preferably, along the projection of the first direction a, the first circuit board 24 and the second circuit board 25 overlap with the heat exchange module 22, or the first circuit board 24 and the second circuit board 25 are completely located within the projection of the heat exchange module 22, so that the heat exchange range of the heat exchange module 22 completely covers the first circuit board 24 and the second circuit board 25, further improving the heat dissipation efficiency of the entire motor control device.

[0105] Combine Figures 5 to 7 As shown, located Figure 5 Above the middle base plate 302 , the heat exchange module 22 , the power module 21 , the copper busbar support 23 and the first circuit board 24 are stacked in order from bottom to top.

[0106] Combine Figure 5 and Figure 8 As shown, located Figure 5 A second circuit board 25 is disposed below the middle substrate 302 .

[0107] A plurality of mounting posts are provided on the base plate 302 for mounting the copper busbar support 23 , the first circuit board 24 and the second circuit board 25 .

[0108] The power module 21 is used for DC / AC conversion, and the AC output of the power module 21 is connected to the copper busbar bracket 23. The copper busbar bracket 23 is an insert-molded structure for the three-phase output copper busbar. One end of the three-phase output copper busbar is electrically connected to the AC output of the power module 21, and the other end of the three-phase output copper busbar is used to connect to the motor. One of the first circuit board 24 and the second circuit board 25 serves as the driver board, and the other serves as the control board. The power module 21 is connected to the first circuit board 24 and the second circuit board 25. In addition, the first circuit board 24 and the second circuit board 25 are used to collect current or voltage signals at each node of the multi-in-one bridge and control the operating status of each component.

[0109] In this embodiment, the use of separate first and second circuit boards (PCBs) 24, 25 separates high and low voltage circuits, preventing signal interference. This also helps increase the total PCB area, facilitating the integration of functions such as the vehicle control unit (VCU), compressor controller, and battery thermal management system (TMS), allowing for greater functionality. Furthermore, the first and second PCBs 24, 25 are located on either side of the heat exchange module 22 along the first direction a. The substrate 302 and heat exchange module 22 also serve as a shielding layer between the first and second PCBs 24, 25, preventing EMC interference between the high and low voltages and significantly improving the product's EMC performance.

[0110] This embodiment adopts a split-board solution. In other alternative embodiments, it is also compatible with a traditional single-board PCB solution. For example, a PCB single board is placed above the capacitor module 11, and the PCB single board is fixedly installed on the housing body 301.

[0111] In this embodiment, the housing 30 includes a base plate 302, which serves as a mounting base for the heat exchange module 22, the power module 21, the copper busbar bracket 23, the first circuit board 24, and the second circuit board 25. In other alternative embodiments, the base plate 302 may not be provided. In such a solution, multiple connecting members may be provided on the side of the housing 30, and the above-mentioned modules may be connected to the housing 30 via the connecting members. For example, the heat exchange module 22 may be connected to the housing 30 via the connecting members. In this case, the heat exchange module 22 can be used as a mounting base to assist in the installation of the power module 21, the copper busbar bracket 23, the first circuit board 24, and the second circuit board 25. The installation method of the above-mentioned modules can be flexibly adjusted based on actual space utilization requirements.

[0112] This embodiment also provides a powertrain, comprising the motor control device described above, a motor, and a reducer. Furthermore, based on the powertrain's integration requirements, the powertrain may further include core components such as an onboard charger (OBC), a DC converter, and a power distribution unit (PDU).

[0113] This embodiment further provides a vehicle including the aforementioned powertrain, wherein the vehicle may be a fuel vehicle, a gas vehicle, or a new energy vehicle, and the new energy vehicle may be a pure electric vehicle, a hybrid vehicle, or an extended-range vehicle.

[0114] The motor control device of this embodiment can also be used for other electrical equipment, wherein the electrical equipment can be the above-mentioned power assembly and vehicle, and can also be a distribution box, mobile phone, portable device, laptop computer, ship, spacecraft, electric toys and electric tools, etc. Spacecraft include airplanes, rockets, space shuttles and spacecraft, etc.; electric toys include fixed or mobile electric toys, such as game consoles, electric car toys, electric ship toys and electric airplane toys, etc.; electric tools include metal cutting power tools, grinding power tools, assembly power tools and railway power tools, such as electric drills, electric grinders, electric wrenches, electric screwdrivers, electric hammers, impact drills, concrete vibrators and electric planers, etc. The embodiments of this application do not impose any special restrictions on the above-mentioned electrical equipment.

[0115] The various embodiments in this specification are described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the various embodiments can be referenced to each other.

[0116] The above description is only a description of the preferred embodiments of the present invention and does not limit the scope of the present invention. Any changes and modifications made by ordinary technicians in the field of the present invention based on the above disclosure shall fall within the scope of protection of the claims.

Claims

1. A motor control device, characterized in that: comprising a first module group and a second module group; The first module group includes a capacitor module and a filter module, and the capacitor module is arranged on one side of the filter module along the first direction; The second module group includes a power module. The second module group is arranged on one side of the first module group along a second direction, and the first direction and the second direction are arranged at an angle.

2. The motor control device according to claim 1, wherein: The first direction and the second direction are perpendicular.

3. The motor control device according to claim 1, wherein: The motor control device further includes a housing, wherein the interior of the housing is divided into at least a first chamber and a second chamber along the first direction, the capacitor module is disposed in the first chamber, and the filter module is disposed in the second chamber.

4. The motor control device according to claim 3, wherein: The motor control device further includes a first connector, one end of which is located in the first cavity and electrically connected to the capacitor module, and the other end of the first connector passes through the first cavity to the second cavity and electrically connected to the filter module.

5. The motor control device according to claim 4, wherein: The motor control device further includes a partition plate, which is disposed between the first chamber and the second chamber. A through groove communicating with the first chamber and the second chamber is formed on the partition plate, and the first connecting member passes through the through groove in a sealed manner.

6. The motor control device according to claim 5, wherein: The motor control device further includes a sealing cover plate, which is sealed to cover the through groove.

7. The motor control device according to claim 6, wherein: A through hole for the first connector to pass through is formed on the sealing cover plate, and the first connector and the inner wall of the through hole are sealed by a sealing member, or the sealing cover plate and the first connector are integrally injection-molded.

8. The motor control device according to claim 3, wherein: The motor control device further includes a filter input terminal, the filter input terminal is located on one side of the housing along the third direction, and the filter input terminal is electrically connected to the filter module; The third direction is perpendicular to the first direction and the second direction.

9. The motor control device according to claim 8, wherein: Along the third direction, the filter input terminal faces the second cavity.

10. The motor control device according to any one of claims 1 to 9, characterized in that: The second module group further includes a heat exchange module, and the power module is arranged in the heat exchange module.

11. The motor control device according to claim 10, wherein: The power module is welded to the heat exchange module by vacuum vapor welding.

12. The motor control device according to claim 10, wherein: The heat exchange module is a water-cooling plate, the water-cooling plate is perpendicular to the first direction, and the power module is arranged on one side of the water-cooling plate along the first direction.

13. The motor control device according to claim 10, wherein: The second module group further includes a first circuit board and a second circuit board, wherein the first circuit board and the second circuit board are respectively located on two sides of the heat exchange module along the first direction.

14. The motor control device according to claim 13, wherein: When the motor control device includes a shell, the shell includes a shell body and a substrate, the first chamber and the second chamber are located in the shell body, the substrate is connected to one side of the shell body along the second direction, and the heat exchange module is arranged on the substrate.

15. The motor control device according to claim 14, wherein: The power module, the heat exchange module and the first circuit board are arranged on one side of the substrate along the first direction, and the second circuit board is arranged on the other side of the substrate along the first direction.

16. A powertrain, characterized in that: The powertrain includes the motor control device according to any one of claims 1 to 15.

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