An integrated assembly, motor controller, and powertrain

Abstract

The embodiment of the present application provides an integrated assembly, a motor controller and a power assembly. The integrated assembly comprises an integrated shell and a capacitor core body, the integrated shell is used for accommodating the capacitor core body, the integrated shell comprises a first surface and a second surface opposite to each other along a first direction, the first surface 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. Along a second direction, the plurality of fixing columns in each row of fixing columns are arranged at intervals, and the plurality of supporting columns in each row of supporting columns are arranged at intervals. Along a third direction, the two rows of supporting columns are arranged at intervals, and the two rows of fixing columns are arranged at intervals between the two rows of supporting columns. The integrated assembly provided by the present application has high integration and strong compactness, can reduce the parts of the motor controller, and reduces the volume of the motor controller.

Description

[0001] This application is a divisional application. The original application has the application number 202311134498.6 and the original application date is August 31, 2023. The entire contents of the original application are incorporated herein by reference. Technical Field

[0002] This application relates to the field of motor controller technology, and in particular to an integrated component, a motor controller, and a powertrain. Background Technology

[0003] Currently, electric vehicles, represented by pure electric and hybrid vehicles, are becoming increasingly popular among consumers. The interior space and comfort of electric vehicles are also constantly increasing. In electric vehicles, the motor controller 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 low integration, which makes the assembly process complicated. The gaps between the various components in the motor controller are large and the compactness is poor, which in turn leads to the large size of the motor controller. Summary of the Invention

[0005] This application provides an integrated component, a motor controller, a powertrain, and a vehicle. The integrated component is applied to the motor controller and features high integration and compactness, reducing the number of components in the motor controller and thus decreasing its size.

[0006] In a first aspect, this application provides an integrated component comprising an integrated housing and a capacitor core. The integrated housing houses the capacitor core. The integrated housing includes a first surface and a second surface opposite each other along a first direction. The first surface of the integrated housing includes two rows of fixing posts and two rows of supporting posts. Along the second direction, each row of fixing posts includes a plurality of fixing posts spaced apart along the second direction, and each row of supporting posts includes a plurality of supporting posts spaced apart. Along a third direction, two rows of supporting posts are spaced apart, and two rows of fixing posts are arranged between the two rows of supporting posts. In this embodiment, the supporting posts and fixing posts are arranged on the same side of the integrated housing, and the two rows of fixing posts are arranged between the two rows of supporting posts, which improves the compactness of the integrated housing layout and reduces the volume of the integrated housing. The two rows of supporting posts are used to fix the circuit board, and the two rows of fixing posts are used to fix the liquid cooling heat sink. The liquid cooling heat sink and the circuit board are fixed to the integrated housing by the supporting posts and fixing posts, respectively, thereby improving the integration degree of the integrated housing. When the integrated component is applied to a motor controller, the motor controller includes fewer components, which is beneficial for the miniaturization of the motor controller.

[0007] In one embodiment, the first surface of the integrated housing includes a row of Hall effect magnetic cores. The row of Hall effect magnetic cores includes multiple Hall effect magnetic cores. The integrated housing integrates the Hall effect magnetic cores, improving the integration density of the integrated housing and the compactness of the motor controller, which is beneficial for the miniaturization of the motor controller. Along a second direction, the multiple Hall effect magnetic cores are arranged at intervals, with each Hall effect magnetic core arranged between two support pillars. This prevents interference between the power module and the support pillars when the power module is mounted on the integrated housing.

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

[0009] In one embodiment, the integrated component includes multiple copper busbar connectors. Each copper busbar connector is used for electrically connecting a power module. Each Hall core includes a core through-hole, and each core through-hole is used to pass through a copper busbar connector in three directions. Along the first and second directions, there is a gap between the copper busbar connector and the inner wall of the core through-hole to ensure that alternating current can stably pass through the Hall core.

[0010] In one embodiment, the second side of the integrated housing includes a filter cavity for accommodating a filter, the opening of which faces along a first direction. The filter is used for electrical connection with the capacitor core, and the opening of the filter cavity on the second side allows for more efficient use of the mounting space of the integrated housing.

[0011] Secondly, this application provides a motor controller comprising multiple power modules, a liquid-cooled heat sink, and an integrated component as described in any of the technical solutions in the first aspect. Each power module includes at least one power transistor. Each power transistor is electrically connected to a capacitor core, and the integrated housing includes two coolant through-holes. Along a first direction, the two coolant through-holes respectively penetrate the integrated housing. Along a second direction, the two coolant through-holes are arranged at intervals to facilitate communication between the coolant through-holes and the liquid-cooled heat sink. Both coolant through-holes pass through the integrated housing, and when the refrigerant passes through the two coolant through-holes, the two coolant through-holes can dissipate heat from the capacitor core, thereby enabling the integrated housing to have a heat dissipation function and 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. This reduces the size of the motor controller along the first direction. Along a second direction, the distance between two coolant through-holes is less than the length of the liquid-cooled radiator. This ensures that the refrigerant in the coolant through-holes does not need to be transferred to other pipes or devices during its delivery to the liquid-cooled radiator, resulting in a more compact motor controller and promoting its miniaturization. Along a third direction, the diameter of each coolant through-hole is less than the width of the liquid-cooled radiator. This also ensures that the refrigerant in the coolant through-holes does not need to be transferred to other pipes or devices during its delivery to the liquid-cooled radiator, further enhancing the compactness of the motor controller and promoting its miniaturization.

[0013] In one embodiment, the power module further includes multiple DC power input terminals, each for electrically connecting a power transistor and a capacitor core. The multiple DC power input terminals are arranged sequentially along one side of the liquid-cooled heatsink. The DC power input terminals facilitate the electrical connection between the power transistor and the capacitor core.

[0014] In one embodiment, the motor controller includes a circuit board for controlling the operation of power transistors in multiple power modules. Along a first direction, the multiple power modules are stacked on top of the circuit board to facilitate control of the multiple power modules by the circuit board. The circuit board includes an isolation strip, multiple power transistor signal terminal connection areas, a power supply circuit component mounting area, a control circuit component, and a control signal interface mounting area. Along a second direction, the power supply circuit component mounting area, the control circuit component mounting area, and the control signal interface mounting area are sequentially spaced, as are the multiple power transistor signal terminal connection areas. 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 component mounting area, the control circuit component mounting area, and the control signal interface mounting area are located on the other side of the isolation strip. In this configuration, the isolation strip divides the circuit board into two areas, resulting in higher space utilization of the circuit board. It also reduces interference between the areas on both sides of the isolation strip. This allows for the integration of more devices 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-cooled heat sink and integrated components stacked 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 connecting to a coolant through-hole.

[0016] In one embodiment, the lower housing includes two coolant openings, each connecting to a coolant through-hole, and each coolant opening facing in a first direction to facilitate communication between the coolant opening and the coolant through-hole. In a second direction, the distance between the two coolant openings is less than the length of the liquid-cooled radiator, ensuring that the two coolant openings correspond to the coolant through-hole in the first direction. In a third direction, the diameter of each coolant opening is less than the width of the liquid-cooled radiator to prevent refrigerant leakage when it enters the coolant through-hole via the coolant opening.

[0017] In one embodiment, the lower housing includes two coolant inlets, each coolant inlet being connected to a coolant opening via a coolant channel. The orientation of each coolant opening is along a third direction, and the distance between the two coolant openings along the second direction is less than the length of the liquid-cooled radiator. The coolant inlets are used to allow external refrigerant to flow to the liquid-cooled radiator through one coolant opening and one coolant opening, thereby providing a cooling source for the liquid-cooled radiator.

[0018] In one embodiment, the upper housing includes control signal connector mounting holes and multiple DC connector mounting holes. The control signal connector mounting holes are used to mount control signal connectors, which receive control signals, and the openings of the connectors face a second direction. The mounting holes facilitate electrical connection between the control signal connectors and a control signal interface. The multiple DC connector mounting holes are used to mount multiple DC connectors, and the openings of these holes face at least one direction (either a first direction or a second direction). The multiple DC connectors are used to transmit DC power. The mounting holes facilitate electrical connection between the multiple DC connectors and a filter.

[0019] Thirdly, embodiments of this application provide a powertrain. This powertrain includes a motor and a motor controller as described in any of the technical solutions of the second aspect, the motor controller being electrically connected to the motor. The motor controller is used to convert direct current (DC) supplied by a power source into alternating current (AC), and output the AC power to the motor. Attached Figure Description

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

[0021] Figure 2 A schematic diagram of the vehicle and powertrain provided in the embodiments of this application;

[0022] Figure 3 A schematic diagram of a motor controller provided for an embodiment of this application;

[0023] Figure 3a for Figure 3 An explosion diagram;

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

[0025] Figure 4 Another schematic diagram of the motor controller provided in the embodiments of this application;

[0026] Figure 4a for Figure 4 An explosion diagram;

[0027] Figure 5 Another schematic diagram of the motor controller provided in the embodiments of this application;

[0028] Figure 6 for Figure 5 Top view;

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

[0030] Figure 8 This is a schematic diagram of the Hall magnetic core in the integrated component in the embodiments of this application;

[0031] Figure 9 This is a schematic diagram of the liquid-cooled heat sink and power module in the embodiments of this application;

[0032] Figure 10 This is a top view of the liquid-cooled heat sink and power module in the embodiments of this application;

[0033] Figure 11 This is a bottom view of the liquid-cooled heat sink and power module in the embodiments of this application;

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

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

[0036] Figure 14 A schematic diagram of the upper housing in the motor controller provided in the embodiments of this application;

[0037] Figure 15 for Figure 14 A bottom view;

[0038] Figure 16 This is another schematic diagram of the upper housing of the motor controller provided in the embodiments of this application;

[0039] Figure 17 Another schematic diagram of the motor controller provided in the embodiments of this application;

[0040] Figure 18 for Figure 17 A bottom view;

[0041] Figure 19 for Figure 17 A schematic diagram of the clamping component.

[0042] Figure label:

[0043] 1-Vehicle; 10-Vehicle body; 11-Wheel; 12-Onboard load; 13-External power supply; 2-Powertrain; 20-Power module; 21-Power battery; 22-Motor; 3-Motor controller; 30-Integrated component; 301-Integrated housing; 302-Capacitor core; 3010-Support column; 3011a, 3011b-Limiting component; 30110-Positioning groove; 3012-Fixing column; 3013, 3013a, 3013b-Coolant through hole; 3014-Hall magnetic core; 30140-Core through hole; 30141-Opening; 3015 - Copper busbar connector; 3016- Mounting slot; 3017- Filter chamber; 303- DC output terminal; 31- Liquid cooler; 310- Heatsink mounting hole; 311- Coolant inlet; 312- Coolant outlet; 32- Power module; 320- Power transistor; 321- DC power input terminal; 322- AC power output terminal; 323- Power transistor signal terminal; 33- Circuit board; 33a- Metal trace; 33b- Lower partition; 33c- Power supply circuit component mounting area; 33d- Control circuit component mounting area; 33e- Control signal interface mounting area; 33 0-Power transistor signal terminal connection area; 3300-Power transistor signal terminal interface; 331-Fixing hole; 332-Isolation strip; 333-Control signal interface; 334-Control circuit; 335-Power supply circuit; 34-Filter module; 340-Filter; 341-DC transmission component; 342-Grounding structure; 35-Clamping component; 350-Upper locking part; 3500-Upper connecting plate; 3501-Upper pressure plate; 3502-Guide plate; 351-Lower locking part; 3510-Lower connecting plate; 3511-Lower pressure plate; 3512-Snap; 352-Main body; 35 20 - Connecting section; 3521 - Weight reduction hole; 353 - Clearance opening; 36 - Upper housing; 360 - Sub-side plate; 3600 - Protruding 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 housing; 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 Implementation

[0044] To make the objectives, technical solutions, and advantages of this application clearer, the application will now be described in further detail with reference to the accompanying drawings.

[0045] The motor controller is the core component controlling the electric powertrain in an electric vehicle. Currently, electric vehicles, represented by pure electric and hybrid vehicles, are becoming increasingly popular with consumers, and the interior space and comfort of electric vehicles are also constantly increasing. In electric vehicles, the motor controller is used to convert the direct current provided by the power battery into alternating current to power the drive motor, thereby using the drive motor to drive the wheels of the electric vehicle.

[0046] However, the motor controller contains a large number of parts, and the connections between these parts are complex, making assembly complicated and resulting in larger gaps between components, thus leading to a larger overall size. This larger size is detrimental to the vehicle's layout, and rework or repair requires disassembling each internal component, making the process cumbersome.

[0047] In existing technologies, motor controllers typically employ high-speed communication protocols for signal transmission to improve the signal transmission rate. However, using high-speed communication protocols requires a protective structure within the motor controller. This protective structure complicates assembly and adds more components, resulting in a larger overall size of the controller after assembly, which is detrimental to vehicle layout. Therefore, there is an urgent need for a highly integrated and compact motor controller.

[0048] The terminology used in the following embodiments is for the purpose of describing particular embodiments only and is not intended to be limiting of this application. As used in the specification and appended claims of this application, the singular expressions “a,” “an,” “the,” “the,” “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" as described in this specification mean that one or more embodiments of this application include a specific feature, structure, or characteristic described in connection with that embodiment. Therefore, the phrases "in one embodiment," "in some embodiments," "in other embodiments," "in still other embodiments," etc., appearing in different parts of 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 "comprising," "including," "having," and variations thereof mean "including but not limited to," unless otherwise specifically emphasized.

[0050] In this 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 this embodiment is not limited to an absolute 90-degree intersection angle. Factors such as assembly tolerances, design tolerances, and structural flatness allow for non-absolute perpendicular intersections, permitting small angular errors. For example, 80 to 100 degrees can be understood as a perpendicular relationship within the assembly error range.

[0051] Figure 1 A schematic diagram of the vehicle provided in this application. Please refer to... Figure 1 The vehicle 1 includes a vehicle body 10, wheels 11, a power battery 21, and a powertrain 2. The powertrain 2 is mounted on the vehicle body 10, and the power battery 21 supplies power to the powertrain 2. The powertrain 2 is used to drive the wheels 11 of the vehicle 1. In one embodiment, the vehicle 1 includes wheels 11 and a powertrain 2. The powertrain 2 is used to drive the wheels 11 of the vehicle 1.

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

[0053] Figure 2 This is a schematic diagram of a vehicle and powertrain provided for an embodiment of this application. Figure 2 As shown, vehicle 1 includes vehicle body 10, wheels 11, power battery 21, power module 20, on-board load 12 and powertrain 2.

[0054] In one embodiment, the powertrain 2 includes a motor controller 3 and a motor 22. See also... Figure 2 The power battery 21 supplies power to the motor 22 via the motor controller 3. The motor controller 3 converts the direct current supplied by the power battery 21 into alternating current. The motor 22 receives this 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 another embodiment, the power module 20 is used to supply power to the vehicle load 12.

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

[0057] Figure 3 A schematic diagram of a motor controller provided for an embodiment of this application. Figure 3a for Figure 3 An explosion diagram. Figure 3b for Figure 3 Another diagram of an explosion. Figure 4 Another schematic diagram of the motor controller provided in the embodiments of this application. Figure 4a for Figure 4 An explosion diagram. Figure 5 Another schematic diagram of the motor controller provided in the embodiments of this application. Figure 7 This is another schematic diagram of the integrated components in an embodiment of this application. Figure 6 for Figure 5 A top view. For clarity, 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 component 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 together form a receiving cavity for the motor controller 3. This cavity accommodates the integrated component 30, the liquid-cooled heat sink 31, the 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 a plurality of DC connector mounting holes 361. The control signal connector mounting hole 3601 is used to mount a control signal connector 39. The opening of the control signal connector mounting hole 3601 faces a second direction X. The control signal connector 39 is used to connect to an external signal transmission line. The opening of the control signal connector 39 faces a first direction X. The openings of the plurality of DC connector mounting holes 361 face at least one direction, including the first direction X and the second direction Y. The plurality of DC connector mounting holes 361 are respectively used to mount a plurality of DC connectors.

[0060] In one embodiment, the lower housing 37 includes two coolant inlets 372 and an AC connector mounting hole 373. The two coolant inlets 372 are used to connect to a liquid-cooled radiator 31 and transfer coolant to dissipate heat from the circuit board 33, multiple power modules 32, integrated components 30, and filter module 34 in the motor controller 3. The openings of the two coolant inlets 372 are oriented along the third direction Z. The AC connector mounting hole 373 is used to mount an AC connector, which electrically connects to a three-phase AC power transmission line and a 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. For example... Figure 3 , Figure 3a , Figure 3b As shown, along the second direction Y, AC connector mounting holes 373 are arranged on one side of the housing of the motor controller 3, and multiple DC connector mounting holes 361 are arranged on the other side of the housing of the motor controller 3. Along the second direction, AC connector mounting holes 373 are arranged on one side of the lower housing 37, and multiple DC connector mounting holes 361 are arranged on the other side of the upper housing 36.

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

[0063] In one embodiment, the integrated component 30 includes an integrated housing 301 and a capacitor core 302. The integrated housing 301 is used to house the capacitor core 302.

[0064] In one embodiment, each power module 32 includes at least one power transistor 320. In another embodiment, the power transistors 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 in the integrated assembly 30, and the midpoint of the bridge arm of each phase bridge arm 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 another embodiment, the power transistors 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 in the integrated assembly 30, and the midpoint of the bridge arm of each phase bridge arm 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 DC power output from the power battery 21 through one or more DC connectors mounted in the DC connector mounting hole 361. The filter 340 is used to receive the DC power from the DC transmission element 341.

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

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

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

[0070] Along the second direction Y, coolant through holes 3013a and 3013b are arranged at intervals, and capacitor core 302 is located between coolant through holes 3013a and 3013b. During the process of coolant entering through holes 3013a and 3013b, it can dissipate heat and cool down capacitor core 302.

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

[0072] In one embodiment, along the third direction Z, the diameter of the coolant through holes 3013a and 3013b is smaller than the width of the liquid-cooled radiator 31, so as to ensure that the possibility of leakage of coolant through holes 3013a and 3013b during the process of flowing into the liquid-cooled radiator 31 is small.

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

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

[0075] In this application, the integrated housing 301 integrates coolant through holes 3013a and 3013b. The process of coolant transfer through holes 3013a and 3013b can dissipate heat from the capacitor core 302, thus enabling the integrated housing 301 to dissipate heat from the capacitor core 302. Furthermore, the integration of coolant through holes 3013a and 3013b into the integrated housing 301 improves the integration level of the motor controller, facilitating its miniaturization.

[0076] In one embodiment, the coolant through-hole 3013a and the coolant through-hole 3013b are shaped as oblong, circular, rectangular, or diamond-shaped holes. In another embodiment, a sealing ring is provided between the coolant through-hole 3013a and the coolant inlet and outlet of the liquid-cooled radiator 31 to ensure the sealing between the coolant through-hole 3013a and the coolant inlet and outlet of the liquid-cooled radiator 31.

[0077] In one embodiment, the lower housing 37 includes two coolant channels and two coolant openings 371, each coolant opening 371 being connected to a coolant through hole. Figure 3a As shown, each coolant opening 371 faces along the first direction X. Along the second direction Y, the distance between two coolant openings 371 is less than the length of the liquid-cooled radiator 31. Along the 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 opening 371 and the coolant through-hole, and also ensures that coolant does not leak.

[0078] In one embodiment, the lower housing 37 includes two coolant inlets 372, each coolant inlet 372 being connected to a coolant opening 371 via a coolant passage 370. Figure 3a As shown, the orientation of each coolant opening 371 is along the third direction Z, and the distance between two coolant openings 371 along the second direction Y is less than the length of the liquid-cooled radiator 31. The coolant inlet 372 is used to allow external coolant to flow to the liquid-cooled radiator 31 through a coolant channel 370 and a coolant opening 371, so as to provide coolant to the liquid-cooled radiator 31.

[0079] The two coolant inlets 372, two coolant channels, and two coolant openings 371 form two pipes that provide a cooling source for the liquid-cooled radiator 31. The inlets of both 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, reference is made 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 each other along the 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 limiting member 3011a and a limiting member 3011b. The limiting members 3011a and 3011b are arranged at intervals on the surface of the integrated housing 301. Coolant through holes 3013a and 3013b are located between the limiting members 3011a and 3011b.

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

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

[0084] In one embodiment, two rows of fixing posts 3012, limiting members 3011a and 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 a 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 fix the liquid-cooled heat sink 31.

[0085] In one embodiment, reference is made 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. (Refer to...) Figure 4a , Figure 5 and Figure 6 Each set of four fixed posts 3012 forms a mounting area, and 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 this application, the integrated housing 301 integrates a fixing post 3012, and the liquid cooling radiator 31 is fixed to the integrated housing 301 through the fixing post 3012, thereby improving the integration of the integrated housing 301.

[0088] In one embodiment, the first surface A of the integrated housing 301 includes two rows of support columns 3010. (Refer to...) Figure 4a , Figure 5 and Figure 6 Two rows of support columns 3010, two rows of fixing columns 3012, and limiting members 3011a and 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 opposite to each other on both sides of the two rows of fixing columns 3012.

[0089] In one embodiment, two rows of support columns 3010 are arranged opposite each other on both sides of the liquid-cooled heat sink 31 or the power module 32. The two rows of support columns 3010 are used to fix the circuit board 33. In this application, the integrated housing 301 integrates the two rows of support columns 3010, making the structure of the motor controller 3 compact and highly integrated. This facilitates the miniaturization of the motor controller 3 and reduces the difficulty and cost of disassembling and assembling the internal components of the motor controller 3.

[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, limiting members 3011a and 3011b each integrate a row of support columns 3010. Accordingly, the height of the support columns 3010 along the first direction X is greater than the height of the fixed columns 3012, which can reduce 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 a first direction X. Along a third direction Z, each support column 3010 is fixed to the first surface A of the integrated housing 301 through limiting members 3011a and 3011b.

[0092] In one embodiment, each row of support columns 3010 includes a plurality of support columns 3010 spaced apart along a second direction Y. Along a 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. Correspondingly, the height of the support columns 3010 along the first direction X is also greater than the height of the fixing columns 3012, which can reduce the size of the integrated housing 301 in the first direction X.

[0093] Figure 8 This is a schematic diagram of the Hall effect magnetic core in the integrated component of this application. In one embodiment, the integrated component 30 includes multiple Hall effect magnetic cores 3014 and multiple copper busbar connectors 3015. One end of the copper busbar connector 3015 is used for electrical connection with 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 a second direction Y. Each mounting slot 3016 is used to mount a Hall effect magnetic core 3014. (Refer to...) 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, and limiting members 3011a and 3011b are located on the same side of the integrated housing 301.

[0095] In one embodiment, the Hall magnetic core 3014 is fixed to the mounting groove 3016 by adhesive bonding, so that multiple Hall magnetic cores 3014 are arranged at intervals along the second direction Y.

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

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

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

[0099] Reference Figure 5 , Figure 6 and Figure 8 The copper busbar connector 3015 passes through the magnetic core through hole 30140, and there is no electrical connection between the copper busbar connector 3015 and the Hall magnetic core 3014. In this application, there is a gap 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, so as to ensure the stability of the AC output through the copper busbar connector 3015.

[0100] In one embodiment, a plurality of Hall magnetic cores 3014 are arranged at intervals along a second direction Y. In another embodiment, the limiting member 3011a includes a plurality of Hall magnetic cores 3014. Exemplarily, the plurality of Hall magnetic cores 3014 are integrally formed with the limiting member 3011a. In one embodiment, the Hall magnetic cores 3014 may be made of magnetic materials such as silicon steel or nickel core.

[0101] In one embodiment, a Hall magnetic core 3014 is arranged between two adjacent support columns 3010 along the second direction Y to improve the 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 a second direction Y. (Refer to...) Figure 4a , Figure 5 and Figure 6 Multiple DC output terminals 303 form three sets of DC output terminals 303. The three sets of DC output terminals 303 are respectively used to correspond to three power modules 32. One end of each set of DC output terminals 303 is electrically connected to the power transistor 320 in a power module 32, and the other end of each set of DC output terminals 303 is used to electrically connect to the capacitor core 302.

[0103] In one embodiment, each set of DC output terminals 303 and a copper busbar connector 3015 are arranged opposite to each other. Along the second direction Y, the projection of a copper busbar connector 3015 lies within the projection of a set of DC output terminals 303, ensuring that the copper busbar connector 3015 does not occupy excessive space in the second direction Y, thus improving the compactness of the motor controller. Along the first direction X, the height of the DC output terminals 303 is less than the height of the copper busbar connector 3015, facilitating electrical connection between the DC output terminals 303 and the 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, a 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, which are spaced apart along the second direction Y. A portion of the copper busbar connector 3015 is fixed to the positioning grooves 30110.

[0106] In the above embodiments, the integrated housing 301 can integrate two coolant through holes 3013a and 3013b, two limiting members 3011a and 3011b, two rows of support columns 3010, two rows of fixing columns 3012, and Hall magnetic core 3014, so that the structure of the motor controller 3 is compact and highly integrated, which is conducive to realizing the miniaturization design of the motor controller 3 and reducing the difficulty and cost of disassembling and assembling 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 component 341, and a grounding structure 342. A first side of the integrated housing 301 is used to fix the liquid-cooled heat sink 31 and the circuit board 33, and a second side is used to mount the filter 340. The second side 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 side of the integrated housing 301 via a filter cavity 3017. (Refer to...) Figure 3b and Figure 7 The second surface B of the integrated housing 301 includes a filter cavity 3017. The filter cavity 3017 is used to mount the filter 340.

[0109] In one embodiment, along the first direction X, the grounding structure 342 is electrically connected to the filter 340 and protrudes from the filter cavity 3017. (Refer to...) 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 cooler 31, and protrudes from the filter cavity 3017 along the first direction X. Along the second direction Y, the length of the filter 340 is less than the length of the second surface of the integrated housing 301.

[0110] In this application, the grounding structure 342 is electrically connected to the filter 340, which is away from the liquid-cooled heat sink 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 mounted on the integrated housing 301. In addition, the grounding structure 342 protruding from the second surface can also ensure 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 surface 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 and the second side b are arranged opposite each other, and the third side c and the fourth side d are arranged opposite each other. A copper busbar connector 3015 protrudes from the integrated housing 301. Coolant through holes 3013a and 3013b are located between the first side a and the second side b, with the coolant through hole 3013a closer to the fourth side d and the coolant through hole 3013b closer to the third side c. The distance between the coolant through holes 3013a and 3013b is relatively large, which can ensure the installation of the capacitor core. The coolant through holes 3013a and 3013b are distributed on both sides of the integrated housing 301, which facilitates the integration of components such as the mounting groove 3016, the support column 3010, and the 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 component 341 is connected to the filter 340, and the other end of the DC transmission component 341 is located on one side of the fourth side d. The other end of the DC transmission component 341 extends towards the first surface of the integrated housing 301, thus minimizing interference between the DC transmission component 341 and the copper busbar connector 3015. Since the DC output terminal 303 is arranged opposite to the copper busbar connector 3015, and the position of the DC transmission component 341 is far from the DC output terminal 303, the interference of the DC transmission component 341 on the DC output terminal 303 is smaller than that on 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. For example... 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 3013b and the copper busbar connector 3015.

[0114] In one embodiment, one end of the DC transmission device 341 is electrically connected to the filter 340, and the other end of the DC transmission device 341 is used for electrical connection to a DC connector. For example... Figure 8 As shown, the other end of the DC transmission component 341 is located on one side of the third side c. The other end of the DC transmission component 341 extends along the second direction Y toward the first surface of the integrated housing 301, thereby reducing the interference between the DC transmission component 341 and the copper busbar connectors 3015.

[0115] In one embodiment, the DC transmission element 341 and the signal connector 39 are arranged opposite each other along the second direction Y. Figure 3a , Figure 8 As shown, the DC transmission component 341 and the signal connector 39 are arranged along the second direction Y on both sides of the liquid-cooled heat sink 31, thereby reducing the interference of the DC transmission component 341 on the signal connector 39.

[0116] Figure 9 This is a schematic diagram of the liquid-cooled heat sink and power module in the embodiments of this application. Figure 10 This is a top view of the liquid-cooled heat sink and power module in the embodiments of this application. Figure 11 This is a bottom view of the liquid-cooled heat sink and power module in the embodiments of this application.

[0117] In one embodiment, multiple power modules 32 are fixed to a liquid-cooled heat sink 31. Along a first direction X, the multiple power modules 32 are stacked with the liquid-cooled heat sink 31, and along a second direction Y, the multiple power modules 32 are arranged at intervals. (Refer to...) Figure 4a, Figure 9 , Figure 10 and Figure 11 The power modules 32 are arranged at intervals along the second direction Y on the surface of the liquid-cooled heat sink 31. In this application, the multiple power modules 32 are arranged flat along the second direction Y on the surface of the liquid-cooled heat sink 31, which helps to reduce the length of the motor controller 3 in the first direction X, effectively utilizes the installation area of ​​the liquid-cooled heat sink 31, and thus enables the miniaturization design of the motor controller.

[0118] In one embodiment, the power transistors 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 electrically connected to the capacitor core 302, and the midpoint of the bridge arm of each phase bridge arm circuit is used to output AC power. Exemplarily, the motor controller 3 includes three power modules 32. Each power module 32 includes one phase bridge arm circuit. Each power module 32 includes at least one bridge arm circuit. Each bridge arm circuit includes two power transistors 320. The two power transistors 320 respectively constitute the upper bridge arm switch and the lower bridge arm switch of the 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 another 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 terminals 321 are used to electrically connect to the capacitor core 302 via the DC output terminal 303. The power transistor signal terminals 323 are used to electrically connect to the circuit board 33. The AC power output terminal 322 is used to electrically connect to the copper busbar connector 3015. The power transistor signal terminals 323 are used to electrically connect to the power transistors 320 in the power module 32.

[0121] In one embodiment, multiple DC power input terminals 321 in each power module 32 are arranged on one side of the power module 32 along the third direction Z, and multiple power transistor signal terminals 323 and one AC power output terminal 322 in 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, multiple AC power output terminals 322 of the multiple power modules 32 are arranged sequentially at intervals.

[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 transistor signal terminals 323. For example, each power module 32 includes twelve power transistors 320 and twelve power transistor signal terminals 323. Six power transistors 320 constitute the upper bridge arm switch of a phase bridge arm circuit, and the other six power transistors 320 constitute the lower bridge arm switch of a phase bridge arm circuit. The twelve power transistor signal terminals 323 are used to electrically connect to the control terminals of the twelve power transistors 320.

[0123] like Figure 9 and Figure 10 As shown, the 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 transistor 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 spaced apart. The three AC power output terminals 322 and twelve power transistor 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 spaced apart.

[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 transistor signal terminal 323 is a pin. The power transistor signal terminal 323 is inserted into the circuit board 33 to establish an electrical connection between the power module 32 and the circuit board 33. The circuit board 33 transmits control signals to the power transistor 320 in the power module 32 through the power transistor signal terminal 323. In one embodiment, the liquid-cooled heat sink 31 includes two rows of heat sink mounting holes 310. Figure 10 and Figure 11 As shown, each row of heat sink mounting holes 310 includes four heat sink mounting holes 310. Along the second direction Y, the four heat sink mounting holes 310 are arranged at intervals. In the two rows of heat sink mounting holes 310, the space between the four oppositely arranged heat sink mounting holes 310 is used to arrange a power module 32. The four heat sink mounting holes 310 are used to mate with four mounting posts to stably mount the liquid-cooled heat sink 31 onto the integrated housing 301.

[0127] Figure 12 This is a schematic diagram of the circuit board in an embodiment of this application. Figure 13 This is another schematic diagram of the circuit board in an embodiment of this application. For example... Figure 12 and Figure 13 As shown, the circuit board 33 includes an isolation strip 332, a connection area 330 for multiple power transistor signal terminals, 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 mounting area 33c, the control circuit component mounting area 33d, and the control signal interface mounting area 33e are distributed at intervals in sequence, and multiple power tube signal terminal connection areas 330 are distributed at intervals in sequence.

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

[0130] The control circuit component 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 component 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 mounting 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 from other circuits to the control signal, and improves the reliability of the motor controller 3.

[0132] In this application, the isolation strip 332 is arranged in the middle of the circuit board 33, which can improve the utilization rate of the circuit board 33, and reduce signal interference between the power supply circuit component mounting area 33c and the control circuit component mounting 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 mounting holes 331, each mounting hole 331 for mounting the circuit board 33. (See also...) Figure 12 and Figure 13 Multiple mounting holes 331 are provided on the edge of the circuit board 33.

[0134] Along the first direction X, multiple fixing holes 331 pass through the circuit board 33. The multiple fixing holes 331 are used to cooperate with multiple support posts 3010, so that the circuit board 33 is fixed to the integrated housing 301 by the support posts.

[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, thus 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 strip 332, so as to avoid affecting the isolation effect of the isolation strip 332, thereby improving the reliability of the motor controller 3.

[0137] In one embodiment, reference is made to Figure 11 , Figure 12 and Figure 13 Each power transistor signal terminal connection area 330 includes three rows of power transistor signal terminal interfaces 3300, which 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 transistor signal terminal interfaces 3300 includes three power transistor signal terminal interfaces 3300. Each power transistor signal terminal interface 3300 is used to electrically connect the power transistor signal terminal of a power transistor to realize signal transmission between the circuit board 33 and the power module.

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

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

[0141] Figure 14 This is a schematic diagram of the upper housing of the motor controller provided in the embodiments of this application. Figure 15 for Figure 14 A bottom view. Figure 16 Another schematic diagram of the upper housing of the motor controller provided in the embodiments of this 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 penetrates the upper housing 36, ensuring 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 this application, the control signal shielding protrusion 362 is integrally formed with the upper housing 36. In the motor controller 3, there is no need to set up a shielding structure for shielding the control signal interface 333 separately, which simplifies assembly and reduces costs.

[0146] In one embodiment, the circuit board 33 includes metal traces 33a and a lower partition 33b. (Combined with...) 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. For example... 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 combine to form a shielding cavity, which can improve the shielding effect on the shielded control signal interface 333 and the control signal connector 39, and improve the reliability of the motor controller 3.

[0148] In one embodiment, the two ends of the control signal shielding protrusion 362 are respectively used for fixed connection to both sides of the control signal connector mounting hole 3601. Along the second direction Y, the projected portion of the control signal shielding protrusion 362 surrounds the projected portion of the control signal interface 333. Along the third direction Z, the two ends of the control signal shielding protrusion 362 are distributed on both sides of the control signal connector mounting hole 3601. The control signal shielding protrusion 362 covers the projected portion 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 clearance opening. Along a 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, it completely covers the control signal interface 333. Along a second direction Y, the clearance opening penetrates the annular protrusion 3620, and its projection 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 clearance 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 via a transmission line.

[0150] In one embodiment, the annular protrusion 3620 is a perimeter plate with openings at both ends formed by multiple sub-plates. The perimeter plate has a circular, rectangular, rhomboid, or other irregular shape when projected in the first direction X.

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

[0152] In one embodiment, one of the two connected sub-side plates 360 includes a control signal connector mounting hole 3601. Combined with... 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 plates is smaller than the distance between the control signal interface 333 and the other sub-side plates. One of the two connected sub-side plates includes a control signal connector mounting hole 3601. The small distance between the control signal shielding protrusion 362 and the sub-side plate with the control signal connector mounting hole 3601 facilitates the 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 housing 36 includes a plurality of protruding edges 3600, which are used to be fixedly connected to the lower housing 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 along a first direction X toward the circuit board 33. The openings of the plurality of DC connector mounting holes 361 are oriented in at least one direction, including along the first direction X and along a 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. Combined with... 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 projection of the plurality of 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 can not only reduce electrical interference, but also reduce the assembly difficulty of 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 sub-side plate 360. The opening of the at least one DC connector mounting hole 361 located on the sub-side plate 360 ​​faces along the first direction X. Figure 15 As shown, at least one of the plurality of DC connector mounting holes 361 has its opening facing along the second direction Y.

[0157] In one embodiment, the upper housing 36 includes a connecting plate 364. Combined with... 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, away from the control signal shielding protrusion 362 along the second direction. The connecting plate 364 includes a positioning hole 3640. Along the second direction Y, the positioning hole 3640 mates with the control signal connector mounting hole 3601 to improve 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 this application. Figure 18 for Figure 17 The bottom view, Figure 19 for Figure 17 A schematic diagram of the clamping element. In one embodiment, the motor controller 3 includes a clamping element 35.

[0159] The integrated housing 301 includes a plurality of Hall magnetic cores 3014 arranged along the second direction Y, and two rows of support columns 3010. Each row of support columns 3010 includes a plurality of support columns 3010 spaced apart along the second direction Y. The plurality of Hall magnetic 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, a liquid-cooled heat sink 31 is stacked on an integrated housing 301 along the first direction X. Multiple power modules 32 are arranged on the surface of the liquid-cooled heat sink 31 along the second direction Y. The liquid-cooled heat sink 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 opposing 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 away from the liquid cooler 31, and the other end of the clamping member 35 abuts against the side of the integrated housing 301 away from the liquid cooler 31, so as to fix the liquid cooler 31 and the power module 32 to the integrated housing 301.

[0163] In this application, the clamping member 35 fixes the liquid cooler 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 cooler radiator 31 for maintenance.

[0164] Combination Figure 18 , Figure 19 As shown, the integrated housing 301 includes two coolant through holes 3013. The clamping member 35 includes a clearance opening 353 for circumventing the coolant through holes 3013. Figure 18 As shown, the clamping member 35 is fixed to the liquid cooler 31 and the integrated housing 301, and the clearance opening 353 can prevent the clamping member 35 from interfering with the coolant through hole 3013.

[0165] In one embodiment, the motor controller 3 includes two clamping members 35. For example... Figure 17 As shown, the two clamping members 35 respectively mate with two power modules 32 located at the beginning and end. The beginning refers to the first one along the arrangement direction of the multiple power modules 32, and the 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, which are connected to both ends of the main body 352. Along a 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 fix the power module 32 located at the first or last end on the side opposite to the liquid cooler radiator 31, and the lower engaging portion 351 is used to engage and fix the integrated housing 301 on the side opposite to the liquid cooler 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 away from the upper connecting plate 3500. The guide plate 3502 extends away from the lower engaging portion 351. When the clamping member 35 fixes the power module 32 at the beginning or 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 pressure plate 3501 and the lower engaging portion 351, and the distance between the guide plate 3502 and the lower engaging portion 351 is also greater than the distance between the upper pressure plate 3501 and the lower engaging portion 351. This can be understood as the upper connecting plate 3500, the upper pressure plate 3501, and the guide plate 3502 being connected sequentially, forming an approximately 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 pressure plate 3501 and the lower engaging portion 351 is less than the distance between the power module 32, the liquid cooler 31, and the integrated housing 301 facing away from the liquid cooler 31, to ensure that the upper pressure plate 3501 and the lower engaging portion 351 can stably fix the liquid cooler 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 pressure plate 3511, and a latch 3512. The lower connecting plate 3510, the lower pressure plate 3511, and the latch 3512 are connected sequentially. Along the first direction X, the gap between the upper pressure plate 3501 and the lower pressure plate 3511 is smaller than the distance between the power module 32, the liquid cooler 31, and the integrated housing 301 away from the liquid cooler 31, so as to ensure that the upper pressure plate 3501 and the lower pressure plate 3511 can stably fix the liquid cooler 31 and the power module 32 to the integrated housing 301. The latch 3512 can engage with the edge of the integrated housing 301 away from the power module 32 to improve the stability of the connection between the power module 32, the liquid cooler 31, and the integrated housing 301.

[0169] In one embodiment, a clearance 353 is formed on a lower engaging portion 351 to divide the lower engaging portion 351 into two parts. Alternatively, each clamping member 35 includes two identical lower engaging portions 351, with the clearance 353 forming the gap between the two lower engaging portions 351.

[0170] The main body 352 includes multiple connecting segments 3520, with the included angle between two adjacent connecting segments 3520 being greater than or equal to 90 degrees, so that the main body 352 is approximately U-shaped. Each connecting segment 3520 includes at least one reinforcing rib to improve the strength of the main body. In addition, in order to reduce the weight of the clamping member 35, the main body 352 includes multiple weight-reducing holes 3521, which penetrate the main body 352.

[0171] The above are merely specific embodiments of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A motor controller, characterized in that, The motor controller includes an upper housing, a lower housing, a circuit board, multiple power modules, a liquid-cooled heat sink, and an integrated assembly. The upper housing and the lower housing combine to form a receiving cavity for the motor controller. The circuit board, the multiple power modules, the liquid-cooled heat sink, and the integrated assembly are sequentially stacked and housed within the receiving cavity along a first direction. The multiple power modules are arranged flat on the surface of the liquid-cooled heat sink along a second direction perpendicular to the first direction. The integrated assembly includes a capacitor core and an integrated housing. The integrated housing is used to house the capacitor core and includes a first surface and a second surface opposite to each other along the first direction. The first surface faces the circuit board, and the second surface faces away from the circuit board. The first surface is used to fix the liquid-cooled radiator. The liquid-cooled radiator includes two rows of radiator fixing holes. Each row of radiator fixing holes includes four radiator fixing holes arranged at intervals along the second direction. The liquid-cooled radiator is fixed to the first surface through the radiator fixing holes. The integrated housing also includes two coolant through holes that penetrate the integrated housing along the first direction. The two coolant through holes are arranged at intervals along the second direction, and the capacitor core is located between the two coolant through holes along the second direction. The two coolant through holes are used to connect the two coolant openings of the lower housing and the liquid-cooled radiator and to transfer coolant to the liquid-cooled radiator.

2. The motor controller according to claim 1, characterized in that, The lower housing also includes two coolant openings, each coolant opening is oriented along a first direction, and each coolant opening is used to connect to a coolant through hole; Along the second direction, the distance between the two coolant openings is less than the length of the liquid-cooled radiator; Along a third direction, the diameter of each of the coolant openings is smaller than the 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 also includes two coolant inlets, each coolant inlet being connected to a coolant opening via a coolant channel, and the orientation of each coolant inlet being along the third direction; The two coolant inlets, the two coolant channels, and the two coolant openings form two pipes that provide a cooling source for the liquid-cooled radiator. Each coolant inlet is used to allow external coolant to flow to the liquid-cooled radiator through one of the coolant channels and one of the coolant openings.

4. The motor controller according to claim 3, characterized in that, Both coolant through holes are waist-shaped holes. The four oppositely arranged radiator mounting holes are used to arrange one power module. Each row of radiator mounting holes is used to cooperate with the four mounting posts on the first surface to install the liquid-cooled radiator on the integrated housing.

5. The motor controller according to any one of claims 1-4, characterized in that, The first surface includes two limiting members, which are arranged at intervals on the surface of the integrated housing, 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 1-4, 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.

7. The motor controller according to claim 6, characterized in that, The diameter of each of the coolant through holes is larger than the diameter of the coolant inlet and the coolant outlet. Each of the coolant inlet and one of the coolant through holes, as well as the coolant outlet and another coolant through hole, is provided with a sealing ring.

8. The motor controller according to any one of claims 1-4, characterized in that, The first surface includes a plurality of support columns, which are used to support and fix the circuit board.

9. The motor controller according to claim 8, characterized in that, The circuit board includes a plurality of fixing holes that penetrate the circuit board along the first direction, each fixing hole being used to cooperate with the plurality of support columns to fix the circuit board.

10. The motor controller according to any one of claims 1-4, characterized in that, The first surface includes two rows of support columns, each row of which includes multiple support columns, and the two rows of support columns are arranged at intervals along a third direction.

11. The motor controller according to claim 10, characterized in that, The first surface includes a row of Hall magnetic cores, the row of Hall magnetic cores including a plurality of Hall magnetic cores, the plurality of Hall magnetic cores being arranged at intervals along the second direction.

12. The motor controller according to claim 11, characterized in that, The first surface includes a plurality of mounting slots, which are spaced apart along the second direction. Each mounting slot is used to mount one Hall magnetic core. The integrated assembly includes a plurality of copper busbar connectors, each of which is used to electrically connect to a power module. Each Hall magnetic core includes a core through-hole, and each core through-hole is used to pass through one of the copper busbar connectors along the third direction.

13. The motor controller according to any one of claims 1-4, characterized in that, The circuit board is used to control the operation of the power transistors in the multiple power modules. The circuit board includes an isolation strip, a signal terminal connection area for multiple power transistors, a power supply circuit component mounting area, a control circuit component, and a control signal interface mounting area, wherein: Along the first direction, the plurality of power modules are stacked and arranged on the circuit board respectively; Along the second direction, the power supply circuit assembly mounting area, the control circuit assembly, 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 distributed on one side of the isolation strip, while the power supply circuit assembly mounting area, the control circuit assembly, and the control signal interface mounting area are distributed on the other side of the isolation strip.

14. A powertrain, characterized in that, The powertrain includes an electric motor and a motor controller as described in any one of claims 1 to 13, the motor controller being used to drive the electric motor.

15. A vehicle, characterized in that, The vehicle includes a motor controller as described in any one of claims 1-13 or a powertrain as described in claim 14.

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