Integrated assembly, motor controller and power assembly

Abstract

The embodiment of the invention provides an integrated assembly, a motor controller and a power assembly. The integrated assembly comprises an integrated shell and a capacitor core, the integrated shell is used for containing the capacitor core, the integrated shell comprises a first face and a second face which are opposite in the first direction, the first face comprises two rows of fixing columns and two rows of supporting columns, each row of fixing columns comprises a plurality of fixing columns, and each row of supporting columns comprises a plurality of supporting columns. In the second direction, the multiple fixing columns in each row of fixing columns are arranged at intervals, and the multiple supporting columns in each row of supporting columns are arranged at intervals. In the third direction, the two rows of supporting columns are arranged at intervals, and the two rows of fixing columns are arranged between the two rows of supporting columns at intervals. The integrated assembly provided by the invention is high in integration level and high in compactness, parts of the motor controller can be reduced, and the size of the motor controller is reduced.

Description

[0001] This application is a divisional application. The application number of the original application is 202311134498.6, and the original application date is August 31, 2023. The entire content of the original application is incorporated into this application by reference. Technical Field

[0002] The present application relates to the technical field of motor controllers, and in particular to an integrated component, a motor controller, and a powertrain. Background Art

[0003] At present, electric vehicles represented by pure electric and hybrid vehicles are becoming more and more popular among consumers, and the interior space and comfort of electric vehicles are also constantly increasing. The motor controller in the electric vehicle is used to convert the DC power provided by the power battery into AC power to power the drive motor, thereby using the drive motor to drive the wheels of the electric vehicle.

[0004] However, the motor controller has a large number of parts and a low degree of integration, which makes the assembly process of the motor controller complicated. There are large gaps between the various components in the motor controller, and the compactness is poor, which in turn leads to a large size of the motor controller. Summary of the Invention

[0005] The embodiments of the present application provide an integrated component, a motor controller, a powertrain, and a vehicle. The integrated component is applied to the motor controller and has high integration and compactness, which can reduce the number of components in the motor controller and reduce the size of the motor controller.

[0006] In a first aspect, the present application provides an integrated component comprising an integrated housing and a capacitor core. The integrated housing is configured to house the capacitor core. The integrated housing includes a first surface and a second surface opposing each other along a first direction. The first surface of the integrated housing includes two rows of fixing columns and two rows of supporting columns. Along a second direction, each row of fixing columns includes a plurality of fixing columns spaced apart along the second direction, and each row of supporting columns includes a plurality of supporting columns spaced apart. Along a third direction, the two rows of supporting columns are spaced apart, with the two rows of fixing columns arranged between the two rows of supporting columns. In this embodiment, the supporting columns and the fixing columns are arranged on the same side of the integrated housing, with the two rows of fixing columns arranged between the two rows of supporting columns. This improves the compactness of the integrated housing layout and reduces its volume. The two rows of supporting columns are configured to secure a circuit board, and the two rows of fixing columns are configured to secure a liquid-cooled radiator. The liquid-cooled radiator and the circuit board are secured to the integrated housing via the supporting columns and fixing columns, respectively, thereby increasing the integrated housing's level of integration. When the integrated component is applied to a motor controller, the motor controller comprises fewer components, facilitating miniaturization of the motor controller.

[0007] In one embodiment, the first surface of the integrated housing includes a row of Hall cores. The row of Hall cores includes multiple Hall cores. The integrated housing integrates the Hall cores, improving the integration of the integrated housing and the compactness of the motor controller, thereby facilitating miniaturization of the motor controller. Along the second direction, the multiple Hall cores are arranged at intervals, with each Hall core arranged between two support pillars. This prevents interference between the power module and the support pillars when installed in the integrated housing.

[0008] In one embodiment, the first surface of the integrated housing includes a plurality of mounting slots. The plurality of mounting slots are spaced apart along the second direction, and each mounting slot is configured to mount a Hall effect core. The integrated housing includes the mounting slots to facilitate mounting of the Hall effect core.

[0009] In one embodiment, the integrated assembly includes multiple copper busbar connectors. Each copper busbar connector is commonly used to electrically connect a power module. Each Hall core includes a core through-hole, each core through-hole being adapted to receive a copper busbar connector along three directions. A gap exists between the copper busbar connector and the inner wall of the core through-hole along the first and second directions to ensure stable passage of alternating current through the Hall core.

[0010] In one embodiment, the second side of the integrated housing includes a filter cavity for accommodating a filter, with an opening of the filter cavity facing in the first direction. The filter is electrically connected to the capacitor core, and the opening of the filter cavity is on the second side, thereby improving the utilization of the installation space of the integrated housing.

[0011] In a second aspect, the present application provides a motor controller, which includes a plurality of power modules, a liquid-cooled radiator and an integrated component in any technical solution in the first aspect. Each power module includes at least one power tube. Each power tube is electrically connected to the capacitor core, and the integrated shell includes two coolant through holes. Each power tube is electrically connected to the capacitor core, and the integrated shell includes two coolant through holes. Along the first direction, the two coolant through holes respectively penetrate the integrated shell. Along the second direction, the two coolant through holes are arranged at intervals so that the coolant through holes are connected to the liquid-cooled radiator. Both coolant through holes pass through the integrated shell, and when the refrigerant passes through the two coolant through holes, the two coolant through holes can dissipate heat for the capacitor core, so that the integrated shell has a heat dissipation function, thereby improving the compactness of the motor controller.

[0012] In one embodiment, the liquid-cooled radiator and the integrated housing are stacked along a first direction. The size of the motor controller along the first direction can be reduced. Along the second direction, the distance between the two coolant through-holes is smaller than the length of the liquid-cooled radiator. This ensures that the refrigerant in the coolant through-hole does not need to be transferred to other pipes or devices during the process of being transported to the liquid-cooled radiator, making the motor controller more compact and facilitating the miniaturization of the motor controller. Along the third direction, the aperture of each coolant through-hole is smaller than the width of the liquid-cooled radiator. This ensures that the refrigerant in the coolant through-hole does not need to be transferred to other pipes or devices during the process of being transported to the liquid-cooled radiator, making the motor controller more compact and facilitating the miniaturization of the motor controller.

[0013] In one embodiment, the power module further includes multiple DC power input terminals, each of which is used to electrically connect a power transistor and a capacitor core. The multiple DC power input terminals are arranged sequentially along one side of the liquid-cooled heat sink. The DC power input terminals facilitate electrical connection between the power transistor and the capacitor core.

[0014] In one embodiment, a motor controller includes a circuit board for controlling the operation of power transistors in multiple power modules. The multiple power modules are stacked on the circuit board along a first direction, enabling the circuit board to control the multiple power modules. The circuit board includes an isolation strip, multiple power transistor signal terminal connection areas, a power supply circuit assembly mounting area, a control circuit assembly mounting area, and a control signal interface mounting area. Along a second direction, the power supply circuit assembly mounting area, the control circuit assembly mounting area, and the control signal interface mounting area are sequentially spaced apart, and the multiple power transistor signal terminal connection areas are sequentially spaced apart. Along a third direction, the multiple power transistor signal terminal connection areas are located on one side of the isolation strip, while the power supply circuit assembly mounting area, the control circuit assembly mounting area, and the control signal interface mounting area are located on the other side of the isolation strip. In this arrangement, the isolation strip divides the circuit board into two areas, improving circuit board space utilization and reducing interference between the areas on either side of the isolation strip. This allows for the integration of more components on the circuit board, reducing the number of circuit boards in the motor controller.

[0015] In one embodiment, the motor controller includes an upper housing and a lower housing, with a liquid cooling radiator and integrated components stacked and arranged between the upper and lower housings along a first direction. The space between the upper and lower housings can also accommodate other components of the motor controller. The lower housing includes two coolant channels, each of which is connected to the two coolant through-holes.

[0016] In one embodiment, the lower housing includes two coolant openings, each coolant opening being configured to communicate with a coolant through-hole, and each coolant opening being oriented in a first direction to facilitate communication between the coolant opening and the coolant through-hole. In a second direction, the spacing between the two coolant openings is less than the length of the liquid-cooled radiator. This allows the two coolant openings to correspond to the coolant through-hole in the first direction. In a third direction, the aperture of each coolant opening is less than the width of the liquid-cooled radiator. This prevents refrigerant from leaking when it enters the coolant through-hole through the coolant opening.

[0017] In one embodiment, the lower housing includes two coolant ports, each of which is configured to communicate with a coolant opening via a coolant channel. Each coolant opening is oriented along a third direction, and the spacing between the two coolant openings along a second direction is less than the length of the liquid-cooled radiator. The coolant ports are configured to direct external refrigerant through the coolant opening and the coolant opening to the liquid-cooled radiator, thereby providing a cooling source for the liquid-cooled radiator.

[0018] In one embodiment, the upper housing includes a control signal connector mounting hole and multiple DC connector mounting holes. The control signal connector mounting hole is used to mount a control signal connector, which is used to receive control signals, and the opening of the signal connector is oriented along the second direction. The provision of the control signal connector mounting hole facilitates electrical connection between the control signal connector and the control signal interface. The multiple DC connector mounting holes are respectively used to mount multiple DC connectors, and the openings of the multiple DC connector mounting holes are oriented along at least one of the first direction and the second direction. The multiple DC connectors are respectively used to transmit direct current. The provision of the multiple DC connector mounting holes facilitates electrical connection between the multiple DC connectors and the filter.

[0019] In a third aspect, embodiments of the present application provide a powertrain. The powertrain includes a motor and a motor controller according to any of the technical solutions of the second aspect, the motor controller being electrically connected to the motor. The motor controller is configured to convert direct current (DC) power provided by a power supply into alternating current (AC) power and output the AC power to the motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 A schematic diagram of a vehicle provided in an embodiment of the present application;

[0021] Figure 2 A schematic diagram of a vehicle and powertrain provided in an embodiment of the present application;

[0022] Figure 3 A schematic diagram of a motor controller provided in an embodiment of the present application;

[0023] Figure 3a for Figure 3 Explosion diagram of

[0024] Figure 3bfor Figure 3 Another explosion diagram;

[0025] Figure 4 Another schematic diagram of a motor controller provided in an embodiment of the present application;

[0026] Figure 4a for Figure 4 Explosion diagram of

[0027] Figure 5 Another schematic diagram of a motor controller provided in an embodiment of the present application;

[0028] Figure 6 for Figure 5 A top view of

[0029] Figure 7 This is another schematic diagram of the integrated components in the embodiment of the present application;

[0030] Figure 8 Schematic diagram of the Hall core in the integrated component in an embodiment of the present application;

[0031] Figure 9 Schematic diagram of a liquid cooling radiator and a power module in an embodiment of the present application;

[0032] Figure 10 A top view of the liquid cooling radiator and power module in an embodiment of the present application;

[0033] Figure 11 A bottom view of the liquid cooling radiator and power module in an embodiment of the present application;

[0034] Figure 12 This is a schematic diagram of a circuit board in an embodiment of the present application;

[0035] Figure 13 This is another schematic diagram of a circuit board in an embodiment of the present application;

[0036] Figure 14 A schematic diagram of the upper housing of the motor controller provided in an embodiment of the present application;

[0037] Figure 15 for Figure 14 Bottom view of

[0038] Figure 16 Another schematic diagram of the upper housing of the motor controller provided in an embodiment of the present application;

[0039] Figure 17 Another schematic diagram of a motor controller provided in an embodiment of the present application;

[0040] Figure 18 for Figure 17 Bottom view of

[0041] Figure 19 for Figure 17 Schematic diagram of the clamping parts.

[0042] Reference numerals:

[0043] 1-Vehicle; 10-Vehicle body; 11-Wheels; 12-Onboard load; 13-External power supply; 2-Powertrain; 20-Power module; 21-Power battery; 22-Motor; 3-Motor controller; 30-Integrated assembly; 301-Integrated housing; 302-Capacitor core; 3010-Support column; 3011a, 3011b-Limiting members; 30110-Locking slot; 3012-Fixing column; 3013, 3013a, 3013b-Coolant hole; 3014-Hall core; 30140-Core hole; 30141-Opening; 3015 - copper busbar connector; 3016 - mounting slot; 3017 - filter cavity; 303 - DC output terminal; 31 - liquid cooling radiator; 310 - radiator fixing hole; 311 - cooling liquid inlet; 312 - cooling liquid outlet; 32 - power module; 320 - power tube; 321 - DC power input terminal; 322 - AC power output terminal; 323 - power tube signal terminal; 33 - circuit board; 33a - metal trace; 33b - lower partition; 33c - power supply circuit component installation area; 33d - control circuit component installation area; 33e - control signal interface installation area; 33 0-power tube signal terminal connection area; 3300-power tube signal terminal interface; 331-fixing hole; 332-isolation belt; 333-control signal interface; 334-control circuit; 335-power supply circuit; 34-filter module; 340-filter; 341-DC transmission element; 342-grounding structure; 35-clamping piece; 350-upper clamping part; 3500-upper connecting plate; 3501-upper pressure plate; 3502-guide plate; 351-lower clamping part; 3510-lower connecting plate; 3511-lower pressure plate; 3512-buckle; 352-main body; 35 20-connecting section; 3521-weight reduction hole; 353-avoidance; 36-upper shell; 360-sub-side plate; 3600-convex edge; 3601-control signal connector mounting hole; 361-DC connector mounting hole; 362-control signal shielding protrusion; 3620-annular protrusion; 363-DC shielding protrusion; 364-connecting plate; 3640-positioning hole; 37-lower shell; 370-coolant channel; 371-coolant opening; 372-coolant interface; 373-AC connector mounting hole; 38-three-phase copper busbar assembly; 39-control signal connector. DETAILED DESCRIPTION

[0044] In order to make the purpose, technical solutions and advantages of this application clearer, this application will be further described in detail below with reference to the accompanying drawings.

[0045] The motor controller is a core component that controls the electric powertrain in electric vehicles. Currently, electric vehicles, represented by pure electric and hybrid vehicles, are becoming increasingly popular among consumers, and the interior space and comfort of electric vehicles are also constantly increasing. The motor controller in an electric vehicle is used to convert the DC power provided by the power battery into AC power to power the drive motor, which in turn drives the wheels of the electric vehicle.

[0046] However, the large number of parts in a motor controller and the complex connections between them complicate assembly, leading to large gaps between components and, consequently, a large motor controller size. This large size is detrimental to overall vehicle layout, and during rework or repair, the internal components must be disassembled one by one, making assembly and disassembly cumbersome.

[0047] In existing technology, motor controllers typically use high-speed communication protocols for signal transmission to increase the signal transmission rate of electronic controllers. However, using high-speed communication protocols for signal transmission requires a protective structure within the motor controller. This installation complicates assembly of the motor controller and further increases the number of parts required. This results in a larger motor controller after assembly, which is detrimental to the overall vehicle layout. Therefore, a highly integrated, compact motor controller is urgently needed.

[0048] The terms used in the following embodiments are only for the purpose of describing specific embodiments and are not intended to limit the present application. As used in the specification and appended claims of this application, the singular expressions "a", "an", "said", "above", "the", and "this" are intended to also include expressions such as "one or more", unless the context clearly indicates otherwise.

[0049] References to "one embodiment" or "some embodiments" in this specification mean that a particular feature, structure, or characteristic described in conjunction with that embodiment is included in one or more embodiments of the present application. Thus, phrases such as "in one embodiment," "in some embodiments," "in other embodiments," and "in yet other embodiments" appearing in various places in this specification do not necessarily refer to the same embodiment, but rather mean "one or more but not all embodiments," unless otherwise specifically emphasized. The terms "including," "comprising," "having," and variations thereof mean "including but not limited to," unless otherwise specifically emphasized.

[0050] In the present application, the first direction X, the second direction Y, and the third direction Z are perpendicular to each other. It should be noted that the perpendicularity defined in the embodiments of the present application is not limited to an absolute intersection angle of 90 degrees. It allows for a relationship that is not absolutely perpendicular due to factors such as assembly tolerance, design tolerance, and the influence of structural flatness, and allows for errors in a small angle range. For example, 80 to 100 degrees can be understood as a perpendicular relationship within the assembly error range.

[0051] Figure 1 Schematic diagram of the vehicle provided for this application. Figure 1 Vehicle 1 includes a vehicle body 10, wheels 11, a power battery 21, and a powertrain 2. Powertrain 2 is mounted on vehicle body 10, and power battery 21 supplies power to powertrain 2. Powertrain 2 is used to drive wheels 11 of vehicle 1. In one embodiment, vehicle 1 includes wheels 11 and powertrain 2. Powertrain 2 is used to drive wheels 11 of vehicle 1.

[0052] In the present application, vehicle 1 includes an electric vehicle (EV), a battery electric vehicle (BEV), a hybrid electric vehicle (HEV), a range extended electric vehicle (REEV), a plug-in hybrid electric vehicle (PHEV) or a new energy vehicle (NEV).

[0053] Figure 2 Schematic diagram of the vehicle and powertrain provided in the embodiment of the present application. Figure 2 As shown, the vehicle 1 includes a vehicle body 10 , wheels 11 , a power battery 21 , a power module 20 , an on-board load 12 and a powertrain 2 .

[0054] In one embodiment, the powertrain 2 includes a motor controller 3 and a motor 22. Figure 2 The power battery 21 supplies power to the motor 22 via the motor controller 3. The motor controller 3 is used to convert the direct current provided by the power battery 21 into alternating current. The motor 22 receives the alternating current and converts it into kinetic energy to drive the wheels 11.

[0055] In one embodiment, the power module 20 is used to receive power from the external power source 13 and charge the power battery 21. In one embodiment, the power module 20 is used to supply power to the vehicle-mounted load 12.

[0056] In this application, the external power source 13 can be an AC grid, an AC charging station, or a DC charging station. The power module 20 can be a power distribution unit or an onboard charger. The onboard load 12 includes at least one of a compressor, a battery heating module, a seat heating module, and a DC low-voltage power supply.

[0057] Figure 3 A schematic diagram of a motor controller provided in an embodiment of the present application. Figure 3a for Figure 3 Explosion diagram. Figure 3b for Figure 3 Another explosion diagram. Figure 4 Another schematic diagram of a motor controller provided in an embodiment of the present application. Figure 4a for Figure 4 Explosion diagram. Figure 5 Another schematic diagram of a motor controller provided in an embodiment of the present application. Figure 7 This is another schematic diagram of the integrated components in an embodiment of the present application. Figure 6 for Figure 5 For ease of explanation, please refer to Figure 3 、 3a 、 Figure 3b 、 4a 、 Figure 5 、 Figure 6 and Figure 7 .

[0058] In one embodiment, the motor controller 3 includes an integrated assembly 30, a liquid-cooled heat sink 31, multiple power modules 32, a circuit board 33, a filter module 34, an upper housing 36, a lower housing 37, a three-phase copper busbar assembly 38, and a control signal connector 39. The upper housing 36 and the lower housing 37 combine to form a housing for the motor controller 3. The housing is used to accommodate the integrated assembly 30, the liquid-cooled heat sink 31, multiple power modules 32, the circuit board 33, the filter module 34, and the three-phase copper busbar assembly 38.

[0059] In one embodiment, the upper housing 36 includes a control signal connector mounting hole 3601 and multiple DC connector mounting holes 361. The control signal connector mounting hole 3601 is used to mount a control signal connector 39. The control signal connector mounting hole 3601 opens in the second direction X. The control signal connector 39 is used to connect to an external signal transmission line. The control signal connector 39 opens in the first direction X. The multiple DC connector mounting holes 361 open in at least one of the first direction X and the second direction Y. The multiple DC connector mounting holes 361 are respectively used to mount multiple DC connectors.

[0060] In one embodiment, the lower housing 37 includes two coolant ports 372 and an AC connector mounting hole 373. The two coolant ports 372 are used to connect to the liquid-cooled radiator 31 and transmit coolant to dissipate heat from the circuit board 33, multiple power modules 32, integrated components 30, and filter modules 34 in the motor controller 3. The openings of the two coolant ports 372 are oriented along the third direction Z. The AC connector mounting hole 373 is used to install an AC connector, which is used to electrically connect the three-phase AC power transmission line and the three-phase copper busbar assembly 38. The opening of the AC connector mounting hole 373 is oriented along the second direction Y.

[0061] In one embodiment, the housing of the motor controller 3 includes an upper housing 36 and a lower housing 37. Figure 3 、 Figure 3a 、 Figure 3b As shown, along the second direction Y, the AC connector mounting holes 373 are arranged on one side of the housing of the motor controller 3, and the plurality of DC connector mounting holes 361 are arranged on the other side of the housing of the motor controller 3. Along the second direction, the AC connector mounting holes 373 are arranged on one side of the lower housing 37, and the plurality of DC connector mounting holes 361 are arranged on the other side of the upper housing 36.

[0062] In one embodiment, the circuit board 33, multiple power modules 32, the liquid-cooled heat sink 31, and the integrated assembly 30 are stacked along a first direction X. In one embodiment, the liquid-cooled heat sink 31 and the integrated assembly 30 are stacked along the first direction X between the upper housing 36 and the lower housing 37. In one embodiment, multiple power modules 32 are arranged between the liquid-cooled heat sink 31 and the circuit board 33 along the first direction X. In one embodiment, each power module 32 is stacked with the circuit board 33 along the first direction X.

[0063] In this embodiment, the integrated assembly 30 includes an integrated housing 301 and a capacitor core 302. The integrated housing 301 is used to accommodate the capacitor core 302.

[0064] In one embodiment, each power module 32 includes at least one power transistor 320. In one embodiment, the power transistors 320 of multiple power modules 32 are used to form a three-phase bridge circuit. The ends of each phase bridge circuit are electrically connected to the capacitor core 302 in the integrated assembly 30, and the midpoint of each phase bridge circuit is used to output AC power to drive the motor 22.

[0065] In one embodiment, each power module 32 includes at least one power transistor 320. In one embodiment, the power transistors 320 of multiple power modules 32 are used to form a three-phase bridge circuit. The ends of each phase bridge circuit are electrically connected to the capacitor core 302 in the integrated assembly 30, and the midpoint of each phase bridge circuit is used to output AC power to drive the motor 22.

[0066] In one embodiment, the filter module 34 includes a filter 340, a DC transmission element 341, and a grounding structure 342. The filter 340 is used to electrically connect the capacitor core 302 in the integrated assembly 30. The DC transmission element 341 is used to receive the DC power output from the power battery 21 via one or more DC connectors installed in the DC connector mounting holes 361. The filter 340 is used to receive the DC power from the DC transmission element 341.

[0067] In the present application, the DC power output by the power battery 21 is transmitted to the filter 340 and the capacitor core 302 via the DC transmission element 341. The filter 340 and the capacitor core 302 are used to reduce the harmonics in the DC power. The three-phase bridge arm circuit composed of the circuit board 33 and multiple power modules 32 receives DC power and outputs AC power to drive the motor 22. Among them, the circuit board 33 is used to control the operation of the power tube 320 in the power module 32. The circuit board 33 receives a control signal through the control signal connector 39 to control the parameters of the AC power output by the inverter circuit. The AC power output by the three-phase bridge arm circuit is transmitted to the three-phase winding of the motor 22 through the three-phase copper busbar assembly 38 and the AC connector fixed by the AC connector mounting hole 373.

[0068] In one embodiment, the integrated housing 301 includes two cooling liquid holes. In one embodiment, the liquid cooling radiator 31 includes a cooling liquid inlet 311 and a cooling liquid outlet 312. The two cooling liquid holes of the integrated housing 301 are used to connect the cooling liquid inlet 311 and the cooling liquid outlet 312 respectively.

[0069] Reference Figure 4a 、 Figure 5 and Figure 6 The two coolant holes are coolant hole 3013a and coolant hole 3013b. Along the first direction X, coolant hole 3013a and coolant hole 3013b extend through integrated housing 301. The projections of coolant holes 3013a and 3013b do not overlap with the projection of capacitor core 302. The refrigerant pipes from coolant holes 3013a and 3013b do not need to avoid capacitor core 302, improving installation convenience.

[0070] Along the second direction Y, the cooling liquid through hole 3013a and the cooling liquid through hole 3013b are arranged at intervals, and the capacitor core 302 is located between the cooling liquid through hole 3013a and the cooling liquid through hole 3013b. When the coolant enters the cooling liquid through hole 3013a and the cooling liquid through hole 3013b, it can dissipate heat and cool down the capacitor core 302.

[0071] In one embodiment, the coolant holes 3013a and 3013b are greater than the length of the capacitor core 302 along the first direction X. In one embodiment, the spacing between the coolant holes 3013a and 3013b along the second direction Y is less than the length of the liquid-cooled heat sink 31. The refrigerant passes through the coolant holes 3013a and 3013b, with the capacitor core 302 located between the coolant holes 3013a and 3013b, thereby cooling the capacitor core 302.

[0072] In one embodiment, along the third direction Z, the apertures of the cooling liquid through hole 3013a and the cooling liquid through hole 3013b are smaller than the width of the liquid-cooled radiator 31 to ensure that the cooling liquid through hole 3013a and the cooling liquid through hole 3013b are less likely to leak when flowing into the liquid-cooled radiator 31.

[0073] In one embodiment, the diameter of the cooling liquid through hole 3013a and the diameter of the cooling liquid through hole 3013b are larger than the cooling liquid inlet and the cooling liquid outlet of the liquid-cooled radiator 31, thereby improving the sealing between the cooling liquid through hole 3013a and the cooling liquid through hole 3013b and the cooling liquid inlet and the cooling liquid outlet of the liquid-cooled radiator 31.

[0074] Reference Figure 4a 、 Figure 5 and Figure 6 The coolant inlet and outlet of the liquid-cooled radiator 31 are connected to the coolant through-hole 3013a and the coolant through-hole 3013b, respectively. For example, the coolant is delivered to the liquid-cooled radiator 31 through the coolant through-hole 3013a, and the coolant in the liquid-cooled radiator 31 flows out through the other coolant through-hole 3013b.

[0075] In the present application, integrated housing 301 integrates coolant through-holes 3013a and 3013b. The process of coolant transmission through coolant through-holes 3013a and 3013b can dissipate heat from capacitor core 302, thus enabling integrated housing 301 to dissipate heat from capacitor core 302. Furthermore, the integration of coolant through-holes 3013a and 3013b into integrated housing 301 can improve the integration of the motor controller and facilitate miniaturization of the motor controller.

[0076] In one embodiment, the shapes of the coolant through-holes 3013a and 3013b are waist-shaped, circular, rectangular, or diamond-shaped. In one embodiment, sealing rings are provided between the coolant through-holes 3013a and 3013b and the coolant inlet and outlet of the liquid-cooled radiator 31 to ensure sealing between the coolant through-holes 3013a and 3013b and the coolant inlet and outlet of the liquid-cooled radiator 31.

[0077] In one embodiment, the lower housing 37 includes two cooling liquid channels 370 and two cooling liquid openings 371, each cooling liquid opening 371 is used to connect to a cooling liquid through hole. Figure 3a As shown, each coolant opening 371 is oriented along a first direction X. Along a second direction Y, the distance between the two coolant openings 371 is less than the length of the liquid-cooled radiator 31. Along a third direction Z, the diameter of each coolant opening 371 is less than the width of the liquid-cooled radiator 31. This facilitates communication between the coolant openings 371 and the coolant through-holes, further preventing coolant leakage.

[0078] In one embodiment, the lower housing 37 includes two coolant interfaces 372, each of which is used to connect to a coolant opening 371 through a coolant channel 370. Figure 3a As shown, each coolant opening 371 is oriented along the third direction Z, and the distance between the two coolant openings 371 along the second direction Y is less than the length of the liquid-cooled radiator 31. The coolant interface 372 is used to flow external coolant through a coolant channel 370 and a coolant opening 371 to the liquid-cooled radiator 31, thereby providing coolant to the liquid-cooled radiator 31.

[0079] The two coolant interfaces 372, the two coolant channels 370, and the two coolant openings 371 form two pipes that provide a cooling source for the liquid-cooled radiator 31. The inlets of the two pipes are connected to the side wall of the lower housing 37, and the outlets of the two pipes are connected to the coolant inlet and coolant outlet of the liquid-cooled radiator 31, respectively.

[0080] In one embodiment, referring to Figure 4a 、 Figure 5 and Figure 6 The integrated housing 301 includes a first surface A and a second surface B that are opposite to each other along a first direction X. The first surface A of the integrated housing 301 can be understood as the side of the integrated housing 301 facing the circuit board 33 , and the second surface B of the integrated housing 301 can be understood as the side of the integrated housing 301 facing away from the circuit board 33 .

[0081] The first surface A of the integrated housing 301 includes a stopper 3011a and a stopper 3011b. The stoppers 3011a and 3011b are spaced apart on the surface of the integrated housing 301. The coolant through hole 3013a and the coolant through hole 3013b are located between the stoppers 3011a and 3011b.

[0082] Reference Figure 4a 、 Figure 5 and Figure 6Along the second direction, the stoppers 3011a and 3011b are arranged on either side of the coolant through-holes 3013a and 3013b. The space between the two spaced-apart stoppers 3011a and 3011b is used to mount the liquid-cooled radiator 31. The stoppers 3011a and 3011b can restrict movement of the liquid-cooled radiator 31 perpendicular to the first direction X and the second direction Y. The stoppers 3011a and 3011b can also restrict movement of the liquid-cooled radiator 31 along the third direction Z, thereby improving the stability of the liquid-cooled radiator 31 integrated into the integrated housing 301.

[0083] In one embodiment, the first surface A of the integrated housing 301 includes two rows of fixing posts 3012. Figure 4a 、 Figure 5 and Figure 6 The two rows of fixing columns 3012 are arranged at intervals between the limiting member 3011a and the limiting member 3011b, and the limiting member 3011a and the limiting member 3011b are used to fix the liquid cooling radiator 31.

[0084] In one embodiment, two rows of fixing posts 3012, stoppers 3011a, and stoppers 3011b are located on the same side of the integrated housing 301. Each row of fixing posts 3012 includes a plurality of fixing posts 3012 spaced apart along the second direction. Along the first direction X, the two rows of fixing posts 3012 are spaced apart along the third direction Z, and the two rows of fixing posts 3012 are used to secure the liquid cooling radiator 31.

[0085] In one embodiment, referring to Figure 4a 、 Figure 5 and Figure 6 , along the third direction Z, two rows of fixed columns 3012 are arranged at intervals.

[0086] In one embodiment, each row of fixing posts 3012 includes four fixing posts 3012 arranged along the second direction Y. Figure 4a 、 Figure 5 and Figure 6 A mounting area is formed between every four fixing columns 3012, and the multiple mounting areas are used to mount the liquid-cooled radiator 31. Along the second direction Y, one mounting area at one end corresponds to the coolant through-hole 3013a, and one mounting area at the other end corresponds to the coolant through-hole 3013b. The coolant inlet and coolant outlet of the liquid-cooled radiator 31 can correspond to the coolant through-hole 3013a and the coolant through-hole 3013b, respectively.

[0087] In the present application, the integrated housing 301 is integrated with the fixing columns 3012 , and the liquid cooling radiator 31 is fixed to the integrated housing 301 through the fixing columns 3012 , thereby improving the integration of the integrated housing 301 .

[0088] In one embodiment, the first side A of the integrated housing 301 includes two rows of support columns 3010. Figure 4a 、 Figure 5 and Figure 6 The two rows of support columns 3010, the two rows of fixing columns 3012, the limiting members 3011a and the limiting members 3011b are located on the same side of the integrated housing 301. Along the second direction Y, the two rows of support columns 3010 are arranged on both sides of the two rows of fixing columns 3012.

[0089] In one embodiment, two rows of support columns 3010 are arranged on opposite sides of the liquid-cooled heat sink 31 or power module 32. The two rows of support columns 3010 are used to secure the circuit board 33. In this application, the integrated housing 301, by integrating two rows of support columns 3010, makes the motor controller 3 compact and highly integrated, facilitating the miniaturization of the motor controller 3 and reducing the difficulty and cost of disassembling and assembling its internal components.

[0090] In one embodiment, each row of support columns 3010 includes a plurality of support columns 3010 spaced apart along the second direction Y. Along the third direction Z, the stoppers 3011a and 3011b each integrate a row of support columns 3010. Accordingly, along the first direction X, the height of the support columns 3010 is greater than the height of the fixing columns 3012, thereby reducing the size of the integrated housing 301 in the first direction X.

[0091] In one embodiment, each row of support columns 3010 includes a plurality of support columns 3010 spaced apart along the first direction X. Along the third direction Z, each support column 3010 is fixed to the first surface A of the integrated housing 301 through a stopper 3011 a and a stopper 3011 b.

[0092] In one embodiment, each row of support columns 3010 includes a plurality of support columns 3010 spaced apart along the second direction Y. Along the third direction Z, two rows of support columns 3010 are spaced apart, and two rows of fixing columns 3012 are spaced apart between the two rows of support columns 3010. The spacing between the two rows of fixing columns 3012 is less than the width of the liquid-cooled radiator 31. Accordingly, along the first direction X, the height of the support columns 3010 is also greater than the height of the fixing columns 3012, thereby reducing the size of the integrated housing 301 in the first direction X.

[0093] Figure 8 This is a schematic diagram of the structure of the Hall effect core in an integrated assembly according to an embodiment of the present application. In one embodiment, the integrated assembly 30 includes multiple Hall effect cores 3014 and multiple copper busbar connectors 3015. One end of the copper busbar connector 3015 is electrically connected to a power transistor 320 to enable AC power output from the power module 32.

[0094] In one embodiment, the first surface A of the integrated housing 301 includes a plurality of mounting slots 3016, which are spaced apart along the second direction Y. Each mounting slot 3016 is used to mount a Hall core 3014. Figure 5 、 Figure 6 、 Figure 7 and Figure 8 The mounting groove 3016 , two rows of support columns 3010 , two rows of fixing columns 3012 , the limiting member 3011 a and the limiting member 3011 b are located on the same side of the integrated housing 301 .

[0095] In one embodiment, the Hall cores 3014 are fixed to the mounting slots 3016 by bonding, so that the plurality of Hall cores 3014 are arranged at intervals along the second direction Y.

[0096] In one embodiment, the limiting member 3011 a includes a mounting groove 3016 , and the Hall core 3014 is bonded to the mounting groove 3016 of the limiting member 3011 a .

[0097] In one embodiment, the Hall core 3014 includes a core through hole 30140 , and the axis of the core through hole 30140 is perpendicular to the first direction X and the second direction Y. Each core through hole 30140 is used to pass a copper busbar connector 3015 .

[0098] In one embodiment, the Hall core 3014 includes an opening 30141. The opening faces away from the integrated housing 301 along the first direction X. The opening 30141 communicates with the core through-hole 30140. The opening 30141 is configured to accommodate a detection device. The detection device is configured to detect current flowing through the copper busbar connector 3015 or voltage across the copper busbar connector 3015.

[0099] Reference Figure 5 、 Figure 6 and Figure 8 The copper busbar connector 3015 is inserted into the magnetic core through-hole 30140, and there is no electrical connection between the copper busbar connector 3015 and the Hall core 3014. In the present application, a gap exists between the copper busbar connector 3015 and the inner wall of the magnetic core through-hole 30140 in the first direction X and the second direction Y to ensure the stability of the AC power output through the copper busbar connector 3015.

[0100] In one embodiment, the plurality of Hall cores 3014 are spaced apart along the second direction Y. In one embodiment, the stopper 3011a includes the plurality of Hall cores 3014. Exemplarily, the plurality of Hall cores 3014 are integrally formed with the stopper 3011a. In one embodiment, the Hall cores 3014 can be made of a magnetic material such as silicon steel or nickel core.

[0101] In one embodiment, along the second direction Y, a Hall core 3014 is arranged between two adjacent support pillars 3010 to improve space utilization of the first surface A of the integrated housing 301 .

[0102] In one embodiment, the integrated component 30 includes a plurality of DC output terminals 303. The plurality of DC output terminals 303 are arranged at intervals along the second direction Y. Figure 4a 、 Figure 5 and Figure 6 The multiple DC output terminals 303 form three groups of DC output terminals 303. The three groups of DC output terminals 303 are respectively used to correspond to three power modules 32. One end of each group of DC output terminals 303 is electrically connected to a power transistor 320 in a power module 32, and the other end of each group of DC output terminals 303 is electrically connected to the capacitor core 302.

[0103] In one embodiment, each set of DC output terminals 303 is arranged opposite one copper busbar connector 3015. Along the second direction Y, the projection of one copper busbar connector 3015 lies within the projection of the set of DC output terminals 303. This ensures that the copper busbar connector 3015 does not occupy additional space in the second direction Y, thereby improving the compactness of the motor controller. Along the first direction X, the height of the DC output terminals 303 is smaller than the height of the copper busbar connector 3015, facilitating electrical connection between the DC output terminals 303 and one copper busbar connector 3015 and the power module.

[0104] In one embodiment, each set of DC output terminals 303 includes two positive DC output terminals and one negative DC output terminal. Along the second direction Y, one negative DC output terminal is arranged between the two positive DC output terminals.

[0105] In one embodiment, the side of the limiting member 3011a facing the limiting member 3011b includes a plurality of positioning grooves 30110 , and the plurality of positioning grooves 30110 are arranged at intervals along the second direction Y. A portion of the copper busbar connector 3015 is fixed to the positioning groove 30110 .

[0106] In the above embodiment, the integrated shell 301 can integrate two coolant through holes 3013a, 3013b, two limit members 3011a, 3011b, two rows of support columns 3010, two rows of fixed columns 3012 and a Hall core 3014, so that the structural layout of the motor controller 3 is compact and highly integrated, which is conducive to realizing the miniaturized design of the motor controller 3 and reducing the difficulty and cost of disassembly and assembly of the internal parts of the motor controller.

[0107] Continue to refer to Figure 7In one embodiment, the filter module 34 includes a filter 340, a DC transmission element 341, and a grounding structure 342. The first surface of the integrated housing 301 is used to secure the liquid-cooled heat sink 31 and the circuit board 33, while the second surface is used to mount the filter 340. The second surface B of the integrated housing 301 includes a filter cavity 3017 for mounting the filter 340.

[0108] In one embodiment, the filter 340 is mounted on the second surface of the integrated housing 301 through the filter cavity 3017. Figure 3b and Figure 7 The second side B of the integrated housing 301 includes a filter cavity 3017 . The filter cavity 3017 is used to install the filter 340 .

[0109] In one embodiment, along the first direction X, the ground structure 342 is electrically connected to the filter 340 and protrudes from the filter cavity 3017. Figure 3b and Figure 8 The grounding structure 342 is mounted on the filter 340 and protrudes from the second surface of the integrated housing 301. The grounding structure 342 is electrically connected to the side of the filter 340 facing away from the liquid-cooled heat sink 31. Along the first direction X, the grounding structure 342 protrudes from the filter cavity 3017. Along the second direction Y, the length of the filter 340 is shorter than the length of the second surface of the integrated housing 301.

[0110] In the present application, the grounding structure 342 is electrically connected to the filter 340, facing away from the liquid-cooled radiator 31, and protrudes from the filter cavity 3017 along the first direction X. The integrated housing 301 is mounted on the lower housing 37, and the grounding structure 342 can abut against the bottom surface of the lower housing, thereby improving the stability of the filter module installed in the integrated housing 301. In addition, the grounding structure 342 protruding from the second surface also ensures that the grounding structure 342 is in contact with the lower housing 37, improving the operational stability of the filter module 34.

[0111] In one embodiment, the second side B of the integrated housing 301 includes a first side a, a second side b, a third side c, and a fourth side d. The first side a is disposed opposite the second side b, and the third side c is disposed opposite the fourth side d. The copper busbar connector 3015 partially protrudes from the integrated housing 301. Coolant holes 3013a and 3013b are located between the first side a and the second side b, with coolant hole 3013a near the fourth side d and coolant hole 3013b near the third side c. The spacing between coolant holes 3013a and 3013b is large enough to ensure the installation of the capacitor core. Coolant holes 3013a and 3013b are located on both sides of the integrated housing 301, facilitating the integration of components such as the mounting slot 3016, support column 3010, and fixing column 3012 into the integrated housing 301.

[0112] In one embodiment, the filter cavity 3017 is arranged between the coolant through-hole 3013a and the copper busbar connector 3015. It can be understood that after the filter 340 is installed in the integrated housing 301, the filter 340 is located between the coolant through-hole 3013a and the copper busbar connector 3015. One end of the DC transmission element 341 is connected to the filter 340, and the other end of the DC transmission element 341 is located on one side of the fourth side d. The other end of the DC transmission element 341 extends toward the first surface of the integrated housing 301, thereby minimizing interference between the DC transmission element 341 and the copper busbar connector 3015. Because the DC output terminal 303 and the copper busbar connector 3015 are arranged opposite each other and the DC transmission element 341 is positioned away from the DC output terminal 303, the DC transmission element 341 interferes less with the DC output terminal 303 than with the copper busbar connector 3015.

[0113] In one embodiment, the filter cavity 3017 is arranged along the third direction Z between the coolant through hole 3013b and the copper busbar connector 3015. Figure 7 As shown, the filter 340 is installed in the filter cavity 3017 of the integrated housing 301 , and the filter 340 is located between the coolant through hole 3013 b and the copper busbar connector 3015 .

[0114] In one embodiment, one end of the DC transmission element 341 is electrically connected to the filter 340, and the other end of the DC transmission element 341 is used to electrically connect to the DC connector. Figure 8 As shown, the other end of the DC transmission component 341 is located on one side of the third side c, and the other end of the DC transmission component 341 extends along the second direction Y toward the first surface of the integrated shell 301, thereby reducing the interference between the DC transmission component 341 and the copper busbar connector 3015.

[0115] In one embodiment, the DC transmission element 341 and the signal connection element 39 are arranged relative to each other along the second direction Y. Figure 3a 、 Figure 8 As shown, the DC transmission component 341 and the signal connection component 39 are arranged on both sides of the liquid cooling radiator 31 along the second direction Y, thereby reducing the interference of the DC transmission component 341 on the signal connection component 39 .

[0116] Figure 9 Schematic diagram of the liquid cooling radiator and power module in an embodiment of the present application. Figure 10 This is a top view of the liquid cooling radiator and power module in an embodiment of the present application. Figure 11 This is a bottom view of the liquid cooling radiator and power module in an embodiment of the present application.

[0117] In one embodiment, multiple power modules 32 are fixed to the liquid cooling radiator 31. Along the first direction X, multiple power modules 32 are stacked and arranged with the liquid cooling radiator 31, and along the second direction Y, multiple power modules 32 are arranged at intervals. Figure 4a、 Figure 9 、 Figure 10 and Figure 11 The power modules 32 are arranged on the surface of the liquid-cooled radiator 31 at intervals along the second direction Y. In the present application, multiple power modules 32 are arranged flat on the surface of the liquid-cooled radiator 31 along the second direction Y, which is beneficial for reducing the length of the motor controller 3 in the first direction X, effectively utilizing the installation area of ​​the liquid-cooled radiator 31, and thus realizing a miniaturized design of the motor controller.

[0118] In one embodiment, the power tubes 320 of multiple power modules 32 are used to form a three-phase bridge arm circuit. The two ends of the bridge arm of each phase bridge arm circuit are used to electrically connect to the capacitor core 302, and the midpoint of the bridge arm of each phase bridge arm circuit is used to output alternating current. Exemplarily, the motor controller 3 includes three power modules 32. Each power module 32 includes a single-phase bridge arm circuit. Each power module 32 includes at least one bridge arm circuit. Each bridge arm circuit includes two power tubes 320. The two power tubes 320 respectively constitute the upper bridge arm switch tube and the lower bridge arm switch tube of the single-phase bridge arm circuit.

[0119] In one embodiment, the power transistor 320 includes at least one of an insulated gate bipolar transistor (IGBT) or a metal-oxide-semiconductor field-effect transistor (MOS). In one embodiment, the power transistor 320 includes a silicon carbide metal-oxide-semiconductor field-effect transistor (SiC MOSFET) or a silicon-insulated-gate bipolar transistor (Si IGBT).

[0120] In one embodiment, each power module 32 includes multiple DC power input terminals 321, one AC power output terminal 322, and multiple power transistor signal terminals 323. The DC power input terminal 321 is electrically connected to the capacitor core 302 via the DC output terminal 303. The power transistor signal terminal 323 is electrically connected to the circuit board 33. The AC power output terminal 322 is electrically connected to the copper busbar connector 3015. The power transistor signal terminal 323 is electrically connected to the power transistor 320 in the power module 32.

[0121] In one embodiment, the multiple DC power input terminals 321 of each power module 32 are arranged on one side of the power module 32 along the third direction Z. The multiple power tube signal terminals 323 and one AC power output terminal 322 of each power module 32 are arranged on the other side of the power module 32 along the third direction Z. Along the second direction Y, the multiple AC power output terminals 322 of the multiple power modules 32 are arranged in sequence and spaced apart.

[0122] like Figure 8 、 Figure 9 As shown, each power module 32 includes three DC power input terminals 321, one AC power output terminal 322, and multiple power tube signal terminals 323. Exemplarily, each power module 32 includes twelve power tubes 320 and twelve power tube signal terminals 323. Six power tubes 320 constitute the upper-arm switching tubes of a single-phase bridge arm circuit, and the remaining six power tubes 320 constitute the lower-arm switching tubes of a single-phase bridge arm circuit. The twelve power tube signal terminals 323 are respectively used to electrically connect the control terminals of the twelve power tubes 320.

[0123] like Figure 9 and Figure 10 As shown, three DC power input terminals 321 of each power module 32 are arranged on one side of the power module 32 along the third direction Z. One AC power output terminal 322 and multiple power tube signal terminals 323 of each power module 32 are arranged on the other side of the power module 32 along the third direction Z.

[0124] The nine DC power input terminals 321 of the three power modules 32 are arranged on one side along the third direction Z. Along the second direction Y, the nine DC power input terminals 321 of the three power modules 32 are arranged at intervals along the second direction Y. The three AC power output terminals 322 and twelve power tube signal terminals 323 of the three power modules 32 are arranged on the other side along the third direction Z. Along the second direction Y, the three AC power output terminals 322 of the three power modules 32 are arranged at intervals.

[0125] Each DC power input terminal 321 extends away from the power module 32 along the third direction Z to facilitate electrical connection between the DC power input terminal 321 and the capacitor core 302. The AC power output terminal 322 of each power module 32 extends away from the power module 32 along the third direction Z to facilitate electrical connection to the copper busbar connector 3015. The power transistor signal terminal 323 of each power module 32 extends away from the power module 32 along the first direction X to facilitate electrical connection to the circuit board 33.

[0126] In one embodiment, the power tube signal terminal 323 is a pin. The power tube signal terminal 323 is inserted into the circuit board 33 to realize the electrical connection between the power module 32 and the circuit board 33. The circuit board 33 transmits the control signal to the power tube 320 in the power module 32 through the power tube signal terminal 323. In one embodiment, the liquid cooling radiator 31 includes two rows of radiator fixing holes 310. Figure 10 and Figure 11 As shown, each row of radiator fixing holes 310 includes four radiator fixing holes 310. Along the second direction Y, the four radiator fixing holes 310 are spaced apart. In two rows of radiator fixing holes 310, a power module 32 is positioned between four opposing radiator fixing holes 310. The four radiator fixing holes 310 are configured to cooperate with four fixing posts to stably mount the liquid cooling radiator 31 to the integrated housing 301.

[0127] Figure 12 This is a schematic diagram of a circuit board in an embodiment of the present application. Figure 13 FIG. 1 is another schematic diagram of a circuit board in an embodiment of the present application. Figure 12 and Figure 13 As shown, the circuit board 33 includes an isolation strip 332, a plurality of power tube signal terminal connection areas 330, a power supply circuit component mounting area 33c, a control circuit component mounting area 33d, and a control signal interface mounting area 33e.

[0128] Along the second direction Y, the power supply circuit component installation area 33c, the control circuit component installation area 33d, and the control signal interface installation area 33e are sequentially spaced apart, and the plurality of power tube signal terminal connection areas 330 are sequentially spaced apart.

[0129] Along the third direction Z, multiple power tube signal terminal connection areas 330 are distributed on one side of the isolation zone 332 , and the power supply circuit component installation area 33c , the control circuit component installation area 33d and the control signal interface installation area 33e are distributed on the other side of the isolation zone 332 .

[0130] The control circuit assembly mounting area 33d is used to mount the circuit components of the control circuit 334, the control signal interface mounting area 33e is used to mount the control signal interface 333, and the power supply circuit assembly mounting area 33c is used to mount the circuit components of the power supply circuit 335. The control signal interface 333 is used to receive control signals, the control circuit 334 is used to control the power transistors 320 in the multiple power modules 32 according to the control signals, and the power supply circuit 335 is used to receive DC power and supply power to the control circuit 334.

[0131] like Figure 13 As shown, the control signal interface installation area 33e is located at the edge of the circuit board 33. Figure 3a As shown, Figure 3aAs shown, the control signal interface 333 is located at the edge of the circuit board 33 , which facilitates the electrical connection between the control signal connector and the control signal interface 333 , reduces interference of other circuits on the control signal, and improves the reliability of the motor controller 3 .

[0132] In the present application, the isolation strip 332 is arranged in the middle of the circuit board 33 to improve the utilization rate of the circuit board 33, and the signal interference between the power supply circuit component installation area 33c and the control circuit component installation area 33d arranged on one side of the isolation strip 332 and the multiple power tube signal terminal connection areas 330 arranged on the other side.

[0133] In one embodiment, the circuit board 33 includes a plurality of fixing holes 331, each fixing hole 331 is used to fix the circuit board 33. Figure 12 and Figure 13 , multiple fixing holes 331 are set at the edge of the circuit board 33.

[0134] A plurality of fixing holes 331 respectively penetrate the circuit board 33 along the first direction X. The plurality of fixing holes 331 are used to cooperate with the plurality of support columns 3010 so that the circuit board 33 is fixed to the integrated housing 301 through the support columns.

[0135] Along the second direction Y, the distance between two adjacent fixing holes 331 is greater than the distance between two adjacent power tube signal terminal connection areas 330, so that the support column 3010 avoids the power tube signal terminal 323 of the power module 32, avoiding affecting the electrical connection between the power tube signal terminal 323 and the circuit board 33, thereby improving the reliability of the motor controller 3.

[0136] Along the third direction Z, the distance between two adjacent fixing holes 331 is greater than the width of the isolation belt 332 , so as to avoid affecting the isolation effect of the isolation belt 332 , thereby improving the reliability of the motor controller 3 .

[0137] In one embodiment, referring to Figure 11 、 Figure 12 and Figure 13 Each power tube signal terminal connection area 330 includes three rows of power tube signal terminal interfaces 3300 , and the three rows of power tube signal terminal interfaces 3300 are used to electrically connect to the power signal terminals 323 in the power module.

[0138] like Figure 12 、 Figure 13 As shown, each row of power tube signal terminal interfaces 3300 includes three power tube signal terminal interfaces 3300. Each power tube signal terminal interface 3300 is used to electrically connect a power tube signal terminal of a power tube to achieve signal transmission between the circuit board 33 and the power module.

[0139] Along the first direction X, each power tube signal terminal interface 3300 penetrates the circuit board 33 to ensure that the power tube signal terminals are electrically connected to the circuit board 33 through the power tube signal terminal interface 3300 in the first direction X. Along the second direction Y, the three power tube signal terminal interfaces 3300 in each row of power tube signal terminal interfaces 3300 are arranged at intervals. Along the third direction Z, the three rows of power tube signal terminal interfaces 3300 in each power tube signal terminal connection area 330 are arranged at intervals.

[0140] In the present application, multiple rows of power tube signal terminal interfaces 3300 of multiple power modules 32 are spaced apart, multiple rows of power tube signal terminal interfaces 3300 of the same power module 32 are spaced apart, and multiple power tube signal terminal interfaces 3300 in the same row of power tube signal terminal interfaces 3300 are spaced apart, which can improve the signal stability of the power tube signal terminal interface 3300 of each power tube 320 in each power module 32.

[0141] Figure 14 A schematic diagram of the upper housing of the motor controller provided in an embodiment of the present application. Figure 15 for Figure 14 Bottom view of . Figure 16 Another schematic diagram of the upper housing of the motor controller provided in an embodiment of the present application.

[0142] In one embodiment, the upper housing 36 includes a control signal shielding protrusion 362 and a control signal connector mounting hole 3601. The control signal connector mounting hole 3601 is used to mount a control signal connector 39. The control signal connector 39 is used to transmit control signals to the control signal interface 333.

[0143] Reference Figure 3a 、 Figure 14 、 Figure 15 and Figure 16 Along the first direction X, the extension direction of the control signal shielding protrusion 362 is toward the circuit board 33, and the projection of the control signal shielding protrusion 362 at least partially surrounds the control signal interface 333 to ensure that the control signal interface 333 is located in the shielding cavity formed by the control signal shielding protrusion 362 and the circuit board 33.

[0144] Along the second direction Y, the projection of the control signal shielding protrusion 362 covers the projection of the control signal connector mounting hole 3601. The control signal connector mounting hole 3601 passes through the upper shell 36, which can ensure that the control signal connector 39 and the control signal connector mounting hole 3601 are electrically connected to the control signal interface 333 located in the control signal shielding protrusion 362.

[0145] In the present application, the control signal shielding protrusion 362 is integrally formed with the upper shell 36 . In the motor controller 3 , there is no need to independently set up a shielding structure for shielding the control signal interface 333 , which can simplify assembly and reduce costs.

[0146] In one embodiment, the circuit board 33 includes metal traces 33a and a lower partition 33b. Figure 3 、 Figure 3a 、 Figure 12 、 Figure 15 As shown, the control signal interface 333 and the lower partition 33b are located at the edge of the circuit board 33. In one embodiment, the area enclosed by the metal traces 33a in the circuit board 33 is larger than the area of ​​the control signal interface 333.

[0147] In one embodiment, the metal trace 33a is located on the side of the circuit board 33 facing the upper housing 36. Figure 3a and Figure 13 As shown, the upper housing 36 is stacked on the circuit board 33, and the control signal shielding protrusion 362 is electrically connected to the metal trace 33a of the circuit board 33. Along the first direction X, the lower partition 33b corresponds to the control signal shielding protrusion 362 and is electrically connected to the metal trace 33a. The metal trace 33a, the lower partition 33b, the control signal shielding protrusion 362, and the upper housing 36 connected to the control signal shielding protrusion 362 form a shielding chamber, which can improve the shielding effect of the control signal interface 333 and the control signal connector 39, thereby improving the reliability of the motor controller 3.

[0148] In one embodiment, the two ends of the control signal shielding protrusion 362 are respectively fixedly connected to the two sides of the control signal connector mounting hole 3601. Along the second direction Y, the projection of the control signal shielding protrusion 362 surrounds the projection of the control signal interface 333. Along the third direction Z, the two ends of the control signal shielding protrusion 362 are arranged on both sides of the control signal connector mounting hole 3601. The control signal shielding protrusion 362 covers the projection of the control signal connector mounting hole 3601, and the control signal connector 39 passes through the control signal connector mounting hole 3601 and is electrically connected to the control signal interface 333 located in the control signal shielding protrusion 362.

[0149] In one embodiment, the control signal shielding protrusion 362 includes an annular protrusion 3620 and a relief opening. Along the first direction X, the projection of the annular protrusion 3620 surrounds the projection of the control signal interface 333. When the annular protrusion 3620 is electrically connected to the circuit board 33, the annular protrusion 3620 completely covers the control signal interface 333. Along the second direction Y, the relief opening passes through the annular protrusion 3620, and the projection of the relief opening covers the projection of the control signal connector mounting hole 3601. The control signal connector 39 passes through the control signal connector mounting hole 3601 and the relief opening and is electrically connected to the control signal interface 333 located in the annular protrusion 3620. The control signal connector 39 is electrically connected to the control signal interface 333, and the control signal connector 39 is electrically connected to the control signal interface 333 via a transmission line.

[0150] In one embodiment, the annular protrusion 3620 is a panel with two open ends formed by a plurality of sub-panels. The panel may be projected in the first direction X in a circular, rectangular, diamond or other irregular shape.

[0151] In one embodiment, the upper housing 36 includes a plurality of sub-side panels 360 extending toward one side of the lower housing 37. The sub-side panels 360 are sequentially connected in pairs. Along the second direction Y, the spacing between the control signal interface 333 and two connected sub-side panels 360 is smaller than the spacing between the control signal interface 333 and the other sub-side panels 360.

[0152] In one embodiment, one of the two connected sub-side panels 360 includes a control signal connector mounting hole 3601. Figure 3 、 Figure 3a 、 Figure 12 、 Figure 13 、 Figure 15 As shown, the distance between the control signal interface 333 and the two connected sub-side panels is smaller than the distance between the control signal interface 333 and the other sub-side panels. Specifically, one of the two connected sub-side panels includes a control signal connector mounting hole 3601, and the control signal shielding protrusion 362 is spaced closely to the sub-side panel having the control signal connector mounting hole 3601. This facilitates electrical connection of the control signal connector to the control signal interface 333 through the control signal connector mounting hole and the control signal shielding protrusion.

[0153] In one embodiment, the upper shell 36 includes a plurality of raised edges 3600 , which are used to be fixedly connected to the lower shell 37 .

[0154] In one embodiment, the upper housing 36 includes a DC shielding protrusion 363 and a plurality of DC connector mounting holes 361. The DC shielding protrusion 363 extends in a first direction X, toward the circuit board 33. The openings of the plurality of DC connector mounting holes 361 face at least one of the first direction X and the second direction Y.

[0155] like Figure 14 As shown, the DC shielding protrusion 363 and the control signal shielding protrusion 362 extend in the same direction. Figure 3 、 Figure 3a and Figure 14 As shown, the projection of the DC shielding protrusion 363 along the first direction X at least partially surrounds the projections of the multiple DC connector mounting holes 361. In this application, the upper housing 36 integrates the DC shielding protrusion 363 and the control signal shielding protrusion 362, which not only reduces electrical interference but also reduces the difficulty of assembling the motor controller 3.

[0156] like Figure 14 As shown, at least one of the plurality of DC connector mounting holes 361 is located on the secondary side plate 360. The opening of the at least one DC connector mounting hole 361 located on the secondary side plate 360 ​​faces along the first direction X. Figure 15 As shown, the opening of at least one DC link installation hole 361 among the plurality of DC link installation holes 361 is oriented along the second direction Y.

[0157] In one embodiment, the upper housing 36 includes a connecting plate 364. Figure 3a 、 Figure 14 、 Figure 16 As shown, the connecting plate 364 is fixed to the side of the sub-side plate 360 ​​where the control signal connector mounting hole 3601 is located, facing away from the control signal shielding protrusion 362 along the second direction. The connecting plate 364 includes a positioning hole 3640. The positioning hole 3640 mates with the control signal connector mounting hole 3601 along the second direction Y, improving the stability of the connection between the control signal connector 39 and the upper housing 36.

[0158] Figure 17 Another schematic diagram of a motor controller is provided for an embodiment of the present application. Figure 18 for Figure 17 Bottom view of Figure 19 for Figure 17 In one embodiment, the motor controller 3 includes a clamping member 35 .

[0159] The integrated shell 301 includes multiple Hall cores 3014 arranged along the second direction Y, and two rows of support columns 3010, each row of support columns 3010 includes multiple support columns 3010 arranged at intervals along the second direction Y, and multiple Hall cores 3014 are located on the side of one row of support columns 3010 away from the other row of support columns 3010.

[0160] like Figure 17 As shown, the liquid cooling radiator 31 is stacked on the integrated housing 301 along a first direction X. A plurality of power modules 32 are arranged on the surface of the liquid cooling radiator 31 along a second direction Y. The liquid cooling radiator 31 is located between two rows of support columns 3010 .

[0161] In one embodiment, along the first direction X, the clamping member 35 includes two opposite ends, and the integrated housing 301 and the liquid-cooling radiator 31 are fixed between the two ends of the clamping member 35 .

[0162] In one embodiment, one end of the clamping member 35 abuts against the surface of the power module 32 facing away from the liquid-cooled radiator 31, and the other end of the clamping member 35 abuts against the side of the integrated shell 301 facing away from the liquid-cooled radiator 31, so as to fix the liquid-cooled radiator 31 and the power module 32 to the integrated shell 301.

[0163] In the present application, the clamping member 35 fixes the liquid cooling radiator 31 and the integrated housing 301 along the first direction X, which can improve the structural stability of the motor controller, simplify the assembly process of the motor controller 3, and also facilitate the disassembly of the liquid cooling radiator 31 for maintenance.

[0164] Combine Figure 18 、 Figure 19 As shown, the integrated housing 301 includes two cooling liquid through holes 3013. The clamping member 35 includes an escape opening 353, which is used to avoid the cooling liquid through holes 3013. Figure 18 As shown, the clamping member 35 is fixed to the liquid cooling radiator 31 and the integrated housing 301 , and the avoidance opening 353 can prevent the clamping member 35 from interfering with the cooling liquid through hole 3013 .

[0165] In one embodiment, the motor controller 3 includes two clamping members 35. Figure 17 As shown, two clamping members 35 are respectively engaged with two power modules 32 located at the head end and the tail end. The head end refers to the first one along the arrangement direction of the multiple power modules 32, and the tail end refers to the last one along the arrangement direction of the multiple power modules 32.

[0166] In one embodiment, the clamping member 35 includes a main body 352, an upper engaging portion 350, and a lower engaging portion 351. The upper engaging portion 350 and the lower engaging portion 351 are connected to both ends of the main body 352. Along the first direction X, the upper engaging portion 350 and the lower engaging portion 351 are located on the same side of the main body 352. The upper engaging portion 350 is used to engage and secure with the side of the power module 32 located at the head end or tail end that faces away from the liquid-cooled radiator 31, and the lower engaging portion 351 is used to engage and secure with the side of the integrated housing 301 that faces away from the liquid-cooled radiator 31. The upper engaging portion 350 includes an upper connecting plate 3500, an upper pressure plate 3501, and a guide plate 3502. The upper connecting plate 3500 connects the upper pressure plate 3501 to the main body 352. The guide plate 3502 is connected to the side of the upper pressure plate 3501 that faces away from the upper connecting plate 3500. The guide plate 3502 extends to a side away from the lower engaging portion 351 . When the clamping member 35 fixes the power module 32 at the head end or the tail end to the integrated housing 301 , the guide plate 3502 included in the clamping member 35 can play a guiding role.

[0167] Along the first direction X, the distance between the upper connecting plate 3500 and the lower engaging portion 351 is greater than the distance between the upper pressing plate 3501 and the lower engaging portion 351. The distance between the guide plate 3502 and the lower engaging portion 351 is also greater than the distance between the upper pressing plate 3501 and the lower engaging portion 351. It can be understood that the upper connecting plate 3500, the upper pressing plate 3501, and the guide plate 3502 are sequentially connected, forming a substantially U-shape, with the U-shaped opening facing away from the lower engaging portion 351. Along the first direction X, the distance between the upper pressing plate 3501 and the lower engaging portion 351 is less than the distance between the power module 32, the liquid-cooled radiator 31, and the integrated housing 301 facing away from the liquid-cooled radiator 31, ensuring that the upper pressing plate 3501 and the lower engaging portion 351 can stably secure the liquid-cooled radiator 31 and the power module 32 to the integrated housing 301.

[0168] The lower engaging portion 351 includes a lower connecting plate 3510, a lower pressing plate 3511, and a buckle 3512. The lower connecting plate 3510, the lower pressing plate 3511, and the buckle 3512 are connected in sequence. Along the first direction X, the spacing between the upper pressing plate 3501 and the lower pressing plate 3511 is smaller than the spacing between the power module 32, the liquid-cooled radiator 31, and the integrated housing 301 away from the liquid-cooled radiator 31. This ensures that the upper pressing plate 3501 and the lower pressing plate 3511 can stably fix the liquid-cooled radiator 31 and the power module 32 to the integrated housing 301. The buckle 3512 can be engaged with an edge of the integrated housing 301 facing away from the power module 32 to improve the stability of the connection between the power module 32, the liquid-cooled radiator 31, and the integrated housing 301.

[0169] In one embodiment, the escape opening 353 is formed on one lower engaging portion 351 to separate the lower engaging portion 351 into two parts. Alternatively, each clamping member 35 includes two identical lower engaging portions 351 , and the gap between the two lower engaging portions 351 serves as the escape opening 353 .

[0170] The main body 352 includes multiple connecting segments 3520. The angle between two adjacent connecting segments 3520 is greater than or equal to 90 degrees, giving the main body 352 a roughly U-shaped shape. Each connecting segment 3520 includes at least one reinforcing rib, which serves to increase the strength of the main body. Furthermore, to reduce the weight of the clamping member 35, the main body 352 includes multiple weight-reducing holes 3521 that extend through the main body 352.

[0171] The above are only specific embodiments of the present application, but the scope of protection of this application is not limited thereto. Any changes or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in this application should be included in the scope of protection of this application. Therefore, the scope of protection of this application should be based on the scope of protection of the claims.

Claims

1. A liquid-cooled integrated motor controller, characterized in that: The motor controller includes an upper shell, a lower shell, a circuit board, multiple power modules, a liquid-cooled radiator, and an integrated component. The upper shell and the lower shell are combined to form a housing cavity of the motor controller. The circuit board, the multiple power modules, the liquid-cooled radiator, and the integrated component are stacked in sequence along a first direction and accommodated in the housing cavity. The multiple power modules are flatly arranged on the surface of the liquid-cooled radiator along a second direction perpendicular to the first direction. The integrated component includes a capacitor core and an integrated shell. The integrated shell is used to accommodate the capacitor core. The cooling liquid of the motor controller flows from the lower shell into the housing cavity and flows through the integrated component and the liquid-cooled radiator in sequence, wherein: The lower shell includes two cooling liquid channels extending along the first direction, and the integrated shell includes two cooling liquid through holes passing through the integrated shell along the first direction. The two cooling liquid through holes are used to connect the two cooling liquid channels and the liquid-cooled radiator, and the liquid-cooled radiator is used to cool and dissipate heat for the multiple power modules.

2. The motor controller according to claim 1, characterized in that: The lower housing further includes two coolant openings, each of the coolant openings is oriented in the first direction, and each of the coolant openings is used to communicate with one of the coolant through holes; Along the second direction, the distance between the two coolant openings is smaller than the length of the liquid-cooled radiator; Along a third direction, a diameter of each of the coolant openings is smaller than a width of the liquid-cooled radiator, and the third direction is perpendicular to the first direction and the second direction.

3. The motor controller according to claim 2, characterized in that: One side wall of the lower housing further includes two coolant interfaces, each of the coolant interfaces being configured to communicate with one of the coolant openings through one of the coolant channels, and each of the coolant interfaces being oriented along the third direction; The two coolant interfaces, the two coolant channels and the two coolant openings form two pipes that provide a cold source for the liquid-cooled radiator. Each coolant interface is used to flow external coolant to the liquid-cooled radiator through one coolant channel and one coolant opening.

4. The motor controller according to claim 3, characterized in that: The shape of each of the coolant openings and each of the coolant through holes is a waist-shaped hole, and the shape of each of the coolant interfaces is a circular hole.

5. The motor controller according to any one of claims 1 to 4, characterized in that: The integrated shell includes a first surface and a second surface opposite to each other along a first direction, the first surface faces the circuit board, and the first surface includes two limiting members, the two limiting members are arranged at intervals on the surface of the integrated shell, and the space between the two limiting members is used to install the liquid cooling radiator.

6. The motor controller according to any one of claims 1 to 5, characterized in that: The capacitor core is located between the two cooling liquid through holes.

7. The motor controller according to any one of claims 1 to 6, characterized in that: The liquid-cooled radiator includes a coolant inlet and a coolant outlet, and the two coolant through holes are used to connect the coolant inlet and the coolant outlet respectively.

8. The motor controller according to claim 7, characterized in that: The diameter of each coolant through hole is larger than the diameter of the coolant inlet and the coolant outlet. The coolant inlet and one coolant through hole, as well as the coolant outlet and another coolant through hole are all provided with sealing rings.

9. The motor controller according to any one of claims 1 to 8, characterized in that: The integrated housing includes an opening, the opening is oriented along a third direction, and the third direction is perpendicular to the first direction and the second direction; Along the first direction, the height of the opening is greater than the height of the capacitor core; Along the second direction, the length of the opening is greater than the length of the capacitor core.

10. The motor controller according to any one of claims 1 to 9, characterized in that: The integrated housing includes a first surface and a second surface opposite to each other along a first direction, the first surface faces the circuit board, and the first surface includes two rows of fixing columns, each row of the fixing columns includes a plurality of the fixing columns arranged at intervals along the second direction.

11. The motor controller according to claim 10, characterized in that: The liquid cooling radiator and the circuit board are both fixedly connected to the first surface of the integrated housing.

12. The motor controller according to any one of claims 1 to 11, characterized in that: The lower shell includes a partition, which extends from the bottom surface of the lower shell along the first direction. The partition divides the lower shell into two sub-cavities. The larger of the two sub-cavities is used to accommodate the integrated component, and the smaller of the two sub-cavities is used to accommodate the filter module of the motor controller.

13. The motor controller according to any one of claims 1 to 11, characterized in that: The circuit board includes a plurality of fixing holes penetrating the circuit board along the first direction, and each of the fixing holes is used to fix the circuit board.

14. The motor controller according to any one of claims 1 to 13, characterized in that: The integrated housing includes a first surface and a second surface opposite to each other along a first direction, the first surface faces the circuit board, and the second surface includes a plurality of fixing members, through which the integrated component is fixed to the bottom surface of the lower housing.

15. The motor controller according to any one of claims 1 to 14, characterized in that: The integrated shell includes a first surface and a second surface opposite to each other along a first direction, the first surface faces the circuit board, the first surface includes two rows of support columns, each row of support columns includes multiple support columns, the ends of the multiple support columns are plug-in structures, the two rows of support columns are arranged at intervals along a third direction, and the two rows of fixing columns are arranged at intervals between the two rows of support columns.

16. The motor controller according to claim 15, characterized in that: The integrated housing includes a first surface and a second surface opposite to each other along a first direction, the first surface faces the circuit board, the first surface includes a row of Hall cores, the row of Hall cores includes a plurality of Hall cores, and the plurality of Hall cores are spaced apart along the second direction.

17. The motor controller according to claim 16, characterized in that: The first surface includes a plurality of mounting slots, which are arranged at intervals along the second direction, and each mounting slot is used to install a Hall core. The integrated component includes a plurality of copper busbar connectors, each of which is used to electrically connect a power module. Each Hall core includes a core through-hole, and each of the core through-holes is used to penetrate a copper busbar connector along the third direction.

18. The motor controller according to any one of claims 1 to 17, characterized in that: The circuit board is used to control the operation of the power tubes in the multiple power modules. The circuit board includes an isolation belt, multiple power tube signal terminal connection areas and a power supply circuit component installation area, a control circuit component, and a control signal interface installation area, wherein: Along the first direction, the multiple power modules are stacked and arranged on the circuit board respectively; Along the second direction, the power supply circuit assembly installation area, the control circuit assembly, and the control signal interface installation area are sequentially spaced apart, and the multiple power tube signal terminal connection areas are sequentially spaced apart; Along the third direction, the multiple power tube signal terminal connection areas are distributed on one side of the isolation zone, and the power supply circuit component installation area, the control circuit component, and the control signal interface installation area are distributed on the other side of the isolation zone.

19. A powertrain, characterized in that: The powertrain includes a motor and a motor controller according to any one of claims 6 to 13, wherein the motor controller is used to drive the motor.

20. A vehicle, characterized in that: The vehicle includes the motor controller according to any one of claims 1 to 18 or the powertrain according to claim 19.

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