Motor controller, control method and electric drive system

Abstract

The invention relates to a motor controller, a control method and an electric drive system. The motor controller comprises a substrate, a control driving module and a power module, the control driving module is arranged on the substrate, a first connecting module and a second connecting module are arranged on the substrate, a first signal input end of the first connecting module is electrically connected with a control signal output end of a vehicle control unit, and a second signal input end of the second connecting module is electrically connected with a control signal output end of the vehicle control unit. A first signal output end of the first connection module is electrically connected with a control signal input end of the control driving module, a second signal input end of the second connection module is electrically connected with a driving signal output end of the control driving module, and a second signal output end of the second connection module is electrically connected with a driving signal input end of the power module; the control driving module is used for determining a driving signal according to the real-time operation data of the target motor and the target operation data; and the power module is used for generating the control signal according to the driving signal so as to control the target motor, and the expandability of the motor controller is improved.

Description

Technical Field

[0001] The present application relates to the field of vehicle control technology, and in particular to a motor controller, a control method, and an electric drive system. Background Art

[0002] New energy vehicles are placing increasingly stringent demands on the size, weight, and power density of electric drive systems. In traditional power control units (PCUs), the driver circuit board, IGBT modules, and busbar capacitors share a single aluminum alloy die-cast housing and are directly interconnected using the shortest copper busbars or solder pads. This maximizes space utilization within the vehicle cabin, shortens the gate drive loop, reduces parasitic inductance, and meets vehicle-level vibration, temperature fluctuation, and electromagnetic compatibility requirements.

[0003] However, with the introduction of the 800 V platform, SiC (silicon carbide) / IGBT (insulated gate bipolar transistor) hybrid packaging, and high switching frequency technology, dv / dt and di / dt have increased dramatically, and the electromagnetic coupling paths within the integrated housing have become increasingly complex, resulting in low scalability of existing motor controllers. Summary of the Invention

[0004] Based on this, it is necessary to provide a motor controller, control method and electric drive system that can flexibly adapt to power modules of different package sizes and voltage levels.

[0005] In a first aspect, the present invention provides a motor controller, comprising a substrate, a control drive module, and a power module, wherein the control drive module is disposed on the substrate, and a first connection module and a second connection module are disposed on the substrate, wherein a first signal input end of the first connection module is electrically connected to a control signal output end of the vehicle controller, a first signal output end of the first connection module is electrically connected to a control signal input end of the control drive module, a second signal input end of the second connection module is electrically connected to a drive signal output end of the control drive module, and a second signal output end of the second connection module is electrically connected to a drive signal input end of the power module;

[0006] The control drive module is used to determine the drive signal for the power module to control the target motor according to the real-time operation data and target operation data of the target motor;

[0007] The power module is used to generate a motor control signal for the target motor according to the driving signal, so as to control the target motor.

[0008] In one embodiment, the control drive module includes a control unit and a drive unit, the control unit and the drive unit are arranged on the same layer on the substrate, the control signal input end is formed on the control unit so that the control unit is electrically connected to the vehicle controller through the first connection module, and the drive signal output end is formed on the drive unit so that the drive unit is electrically connected to the power module through the second connection module;

[0009] The control unit is configured to generate an intermediate signal for the power module to control the target motor according to the real-time operating data and target operating data of the target motor;

[0010] The driving unit is configured to generate a driving signal for the power module to control the target motor according to the intermediate signal.

[0011] In one embodiment, the control unit includes a main control chip, a sampling circuit, a resolver circuit, and a bus circuit. The intermediate signal output terminal of the main control chip is electrically connected to the intermediate signal input terminal of the drive unit. The sampling circuit, the resolver circuit, and the bus circuit are electrically connected to the main control chip. The current sampling input terminal of the sampling circuit is electrically connected to the power module through the second connection module. The resolver signal input terminal of the resolver circuit and the bus signal input terminal of the bus circuit form a control signal input terminal of the control unit and are electrically connected to the first connection module.

[0012] The sampling circuit is used to collect the real-time current of the target motor;

[0013] The resolver circuit is used to collect the real-time resolver signal of the target motor;

[0014] The bus circuit is used to collect the target torque and target speed of the target motor;

[0015] The main control chip is used to determine the real-time torque and real-time speed of the target motor based on the real-time current and the real-time resolver signal, and to generate an intermediate signal for the power module to control the target motor based on the real-time torque, the real-time speed, the target torque and the target speed.

[0016] In one embodiment, the control unit further includes a fault detection circuit electrically connected to the main control chip, and a fault signal input end of the fault detection circuit is electrically connected to the power module through the second connection module;

[0017] The fault detection circuit is used to collect fault data of the power module;

[0018] The sampling circuit is further used to collect the first state data of the target motor and the second state data of the power module;

[0019] The main control chip is further configured to generate monitoring data for monitoring the operating state of the target motor according to the real-time current, the fault data, the first state data, and the second state data.

[0020] In one embodiment, the second connection module includes a first drive connector and a second drive connector; the drive signal includes a voltage-converting drive signal and an inverting drive signal;

[0021] The power module includes at least one transformer circuit and at least one inverter circuit, and the transformer circuit and the inverter circuit are arranged in a one-to-one correspondence. The transformer circuit is electrically connected to the first drive signal output terminal of the drive unit through the first drive connector, the voltage signal input terminal of the transformer circuit is connected to an external power supply, the voltage signal output terminal of the transformer circuit is electrically connected to the voltage input terminal of the inverter circuit, and the inverter circuit is electrically connected to the second drive signal output terminal of the drive unit through the second drive connector;

[0022] The voltage conversion circuit is used to dynamically adjust the power supply voltage input by the external power supply according to the voltage conversion drive signal to obtain a DC drive voltage that matches the voltage level of the inverter circuit;

[0023] The inverter circuit is used to invert the DC drive voltage according to the inverter drive signal to obtain an AC control voltage for controlling the target motor.

[0024] In one embodiment, the voltage conversion circuit includes a first capacitor, a second capacitor, an inductor, a first voltage conversion transistor and a second voltage conversion transistor, the first end of the first capacitor is connected to the positive electrode of the external power supply, the second end of the first capacitor is connected to the negative electrode of the external power supply, the first end of the first capacitor is also electrically connected to the emitter of the first voltage conversion transistor and the collector of the second voltage conversion transistor through the inductor, the collector of the first voltage conversion transistor is electrically connected to the first end of the second capacitor, the second end of the second capacitor is electrically connected to the second end of the first capacitor and the emitter of the second voltage conversion transistor, the gate of the first voltage conversion transistor and the gate of the second voltage conversion transistor are electrically connected to the first drive signal output end of the drive unit through the first drive connector, the first end and the second end of the second capacitor form the voltage signal output end of the voltage conversion circuit and are electrically connected to the voltage input end of the inverter circuit.

[0025] In one embodiment, the inverter circuit includes a first high-voltage transistor, a second high-voltage transistor, a third high-voltage transistor, a first low-voltage transistor, a second low-voltage transistor and a third low-voltage transistor; the gate of the first high-voltage transistor, the gate of the second high-voltage transistor, the gate of the third high-voltage transistor, the gate of the first low-voltage transistor, the gate of the second low-voltage transistor and the gate of the third low-voltage transistor are electrically connected to the second drive signal output end of the drive unit through the second drive connector; the collector of the first high-voltage transistor and the emitter of the first low-voltage transistor are connected to the DC drive voltage, the emitter of the first high-voltage transistor is connected to the collector of the first low-voltage transistor and outputs the first phase voltage, the collector of the second high-voltage transistor and the emitter of the second low-voltage transistor are connected to the DC drive voltage, the emitter of the second high-voltage transistor is connected to the collector of the second low-voltage transistor and outputs the second phase voltage, the collector of the third high-voltage transistor and the emitter of the third low-voltage transistor are connected to the DC drive voltage, the emitter of the third high-voltage transistor is connected to the collector of the third low-voltage transistor and outputs the third phase voltage.

[0026] In one embodiment, the substrate has a high-voltage area and a low-voltage area, the high-voltage area is formed at the edge of the substrate, and the low-voltage area is located on the inner side of the high-voltage area. The second connection module and the driving unit and the sampling circuit in the control drive module are arranged in the high-voltage area, and the first connection module and the main control chip, bus circuit, resolver circuit and fault detection circuit in the control drive module are arranged in the low-voltage area.

[0027] In a second aspect, the present invention provides a control method for a motor controller, which is applied to the motor controller described above, and the method comprises the following steps:

[0028] Acquire real-time operating data and target operating data of the target motor;

[0029] Determining a drive signal for the power module to control a target motor according to the real-time operating data and the target operating data;

[0030] A motor control signal for the target motor is generated according to the drive signal to control the target motor.

[0031] In a third aspect, the present invention provides an electric drive system, comprising the motor controller as described above.

[0032] The above-mentioned motor controller, control method and electric drive system, by setting a control drive module on the substrate, the vehicle controller exchanges signals with the control drive module through the first connection module, and the power module exchanges signals with the control drive module through the second connection module. On the one hand, integrating the control function and drive function of the motor into the substrate can effectively improve the integration of the entire motor controller. At the same time, the transmission path of the drive signal can be shortened, which is conducive to reducing parasitic inductance; on the other hand, the setting of the first connection module and the second connection module enables the power module to be disassembled and assembled with the substrate in a plug-and-play manner, which greatly improves the maintenance and repair efficiency when the power module fails. In addition, the appropriate power module can be flexibly selected according to different packaging sizes and voltage levels, which is conducive to improving the scalability of the motor controller. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the conventional technology, the following briefly introduces the drawings required for use in the embodiments or the conventional technology descriptions. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0034] Figure 1 FIG. 4 is a control block diagram of a motor controller according to an embodiment of the present invention.

[0035] Figure 2 FIG. 4 is a structural block diagram of a motor controller according to an embodiment of the present invention.

[0036] Figure 3 FIG. 1 is a structural block diagram of a control drive module according to an embodiment of the present invention.

[0037] Figure 4 FIG. 4 is a circuit diagram of a power module according to an embodiment of the present invention.

[0038] Figure 5 FIG. 1 is a flow chart of a control method of a motor controller according to an embodiment of the present invention.

[0039] Figure 6 The flowchart is a control method of a motor controller according to an application example.

[0040] Description of reference numerals:

[0041] substrate 100;

[0042] Control drive module 200, control unit 210, main control chip 211, sampling circuit 212, resolver circuit 213, bus circuit 214, fault detection circuit 215, power supply circuit 216, drive unit 220;

[0043] Power module 300, voltage conversion circuit 310, first capacitor C1, second capacitor C2, reactor L, first voltage conversion transistor VCU-H, second voltage conversion transistor VCU-L, inverter circuit 320, first high-voltage transistor UH, second high-voltage transistor VH, third high-voltage transistor WH, first low-voltage transistor UL, second low-voltage transistor VL, third low-voltage transistor WL;

[0044] Vehicle controller 400;

[0045] A first connection module 510 and a second connection module 520;

[0046] Target motor M. DETAILED DESCRIPTION

[0047] To facilitate understanding of the present application, the present application will be described more fully below with reference to the accompanying drawings. The accompanying drawings provide embodiments of the present application. However, the present application may be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to make the disclosure of the present application more thorough and comprehensive.

[0048] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art to which this application pertains. The terms used herein in the specification of this application are for the purpose of describing specific embodiments only and are not intended to limit this application.

[0049] It will be understood that the terms "first," "second," etc., used herein may be used to describe various elements, but these elements are not limited by these terms. These terms are only used to distinguish a first element from another element. For example, a first resistor may be referred to as a second resistor, and similarly, a second resistor may be referred to as a first resistor without departing from the scope of this application. The first resistor and the second resistor are both resistors, but they are not the same resistor.

[0050] It can be understood that the “connection” in the following embodiments should be understood as “electrical connection”, “communication connection”, etc. if there is transmission of electrical signals or data between the connected circuits, modules, units, etc.

[0051] It is understood that “at least one” refers to one or more, “a plurality” refers to two or more, and “at least a portion of an element” refers to a portion or all of an element.

[0052] As used herein, the singular forms "a," "an," and "the" may also include the plural forms, unless the context clearly indicates otherwise. It should also be understood that the terms "include," "comprising," "having," and the like specify the presence of stated features, integers, steps, operations, components, parts, or combinations thereof, but do not preclude the presence or addition of one or more other features, integers, steps, operations, components, parts, or combinations thereof. Furthermore, the term "and / or" as used in this specification includes any and all combinations of the relevant listed items.

[0053] In related technologies, the integrated design of the control, drive, and power modules within the same housing results in the parallel operation of drive wiring with hundreds of volts, making it difficult to further suppress common-mode interference and radiation coupling. This can easily lead to PWM (Pulse Width Modulation) pulse loss or gate mis-triggering under extreme operating conditions. Furthermore, the IGBTs in the power module are directly welded to the driver board, requiring complete disassembly of the housing for replacement or repair, which can take over 30 minutes per operation. Frequent disassembly and assembly, especially during bench testing, severely impacts maintenance efficiency. Furthermore, once the integrated housing is finalized, it is difficult to adapt to IGBTs of different package sizes or voltage levels, resulting in high platform costs.

[0054] like Figure 1 and Figure 2 As shown, a motor controller of an embodiment includes a substrate 100, a control drive module 200 and a power module 300. The control drive module 200 is arranged on the substrate 100. A first connection module 510 and a second connection module 520 are arranged on the substrate 100. The first signal input end of the first connection module 510 is electrically connected to the control signal output end of the vehicle controller 400, the first signal output end of the first connection module 510 is electrically connected to the control signal input end of the control drive module 200, the second signal input end of the second connection module 520 is electrically connected to the drive signal output end of the control drive module 200, and the second signal output end of the second connection module 520 is electrically connected to the drive signal input end of the power module 300.

[0055] The control drive module 200 is used to determine the drive signal for the power module 300 to control the target motor M based on the real-time operation data and target operation data of the target motor M; the power module 300 is used to generate a motor control signal for the target motor M based on the drive signal to control the target motor M.

[0056] The substrate 100 can be implemented using a high-density printed circuit board (PCB). Depending on the size and integration level of the control and drive module 200, the first connection module 510, and the second connection module 520, a single-layer or multi-layer PCB structure can be used to achieve isolation and shielding between the various modules and structures while ensuring high integration.

[0057] The first connection module 510 and the second connection module 520 are disposed on the substrate 100. In a specific implementation, the first connection module 510 and the second connection module 520 can be connected to the substrate 100 by welding. The vehicle controller 400 can be connected to the first connection module 510 via a wiring harness. The end of the first connection module 510 away from the vehicle controller 400 is connected to the control drive module 200. The first connection module 510 and the control drive module 200 can also be connected via a wiring harness or via a circuit printed on the substrate 100. The power module 300 can be connected to the second connection module 520 via a wiring harness. The end of the second connection module 520 away from the power module 300 is connected to the control drive module 200. The second connection module 520 and the control drive module 200 can also be connected via a wiring harness or via a circuit printed on the substrate 100.

[0058] Multiple signal transmission channels can be integrated in the first connection module 510. The controlled motor (i.e., the target motor M) controlled by the motor controller and the vehicle controller 400 can be connected to the first connection module 510 through a wiring harness to realize the interaction of control data between the target motor M, the vehicle controller 400 and the control drive module 200, such as the operating data and status data of the target motor M, and the target operating data set for the target motor M by the vehicle controller 400. The operating data and status data of the target motor M can be monitored by various sensors provided on the target motor M and then transmitted to the control drive module 200 through the corresponding channel of the first connection module 510, so that the control drive module 200 can generate a drive signal for the power module 300 according to these data to control the operation of the target motor M after driving the power module to start.

[0059] In an optional embodiment, the first connection module 510 may include multiple connectors to be electrically connected to the control signal output terminal of the target motor M and the control signal output terminal of the vehicle controller 400, respectively, so as to transmit the status data of the target motor M (such as the temperature signal of the target motor M) and the target operation data output by the vehicle controller 400 to the control drive module 200. In some other embodiments, the first connection module 510 may also be implemented using a single connector, and partitions may be formed on the same connector. The target motor M and the vehicle controller 400 may each be connected to a partition to achieve data exchange between various modules and structures.

[0060] Similar to the first connection module 510, the second connection module 520 may also have multiple signal transmission channels to realize the interaction of driving data between the control drive module 200 and the power module 300, such as the driving signal for driving the power module 300 to operate, etc. The driving signal for driving the power module 300 to operate is generated by controlling the drive module 200 based on the real-time operating data and target operating data of the target motor M.

[0061] In an optional embodiment, the control drive module 200 can be connected to the base plate 100 by welding and can be encapsulated in an aluminum alloy shielding box. An opening is reserved on the outer wall of the aluminum alloy shielding box to expose the first connection module 510 and the second connection module 520, so that the power module 300, the target motor M and the vehicle controller 400 can be connected to the first connection module 510 and the second connection module 520 via a wiring harness, thereby realizing data exchange between the power module 300, the target motor M and the vehicle controller 400 and the control drive module 200.

[0062] The control drive module 200 is used to determine the drive signal for the power module 300 to control the target motor M based on the real-time operation data and target operation data of the target motor M; the power module 300 is used to generate a motor control signal for the target motor M based on the drive signal to control the target motor M.

[0063] The real-time operating data of the target motor M refers to data collected during the actual operation of the target motor M and can be used to reflect the actual operating status of the target motor M. The real-time operating data may include, but is not limited to, the real-time current, real-time voltage, real-time speed, real-time torque, real-time direction, and real-time steering angle of the target motor M. The target operating data refers to the desired operating state of the target motor M, determined based on the operating conditions of the target motor M. The target operating data may include, but is not limited to, target speed, target torque, target direction, and target steering angle. The drive signal refers to the driving force (or voltage) required by the power module 300 to output the corresponding motor control signal when the target motor M reaches the target operating state, as determined based on the real-time operating data and the target operating data. The drive signal may be a regulated PWM signal. The motor control signal refers to the control voltage required for the target motor M to reach the target operating state from its current operating state (real-time operating state). The motor control signal can be obtained by the power module 300 inverting the external power supply under the action of the drive signal.

[0064] Exemplarily, the power module 300 can be connected to at least one controlled motor. During control, the target motor M can be determined according to the control requirements of the controlled motor. The vehicle controller 400 can determine the target operating data of the target motor M according to the operating conditions of the target motor M. Various sensors set on the target motor M can monitor the real-time operating data of the target motor M in real time. The target operating data and real-time operating data of the target motor M can be transmitted to the control drive module 200 through the first connection module 510, so that the control drive module 200 can generate a drive signal for controlling the target motor M according to the target operating data and the real-time operating data. The drive signal can be transmitted to the power module 300 through the second connection module 520 to drive the power module 300 to operate, and then the target motor M is controlled by the motor control signal of the power module 300 data for the target motor M.

[0065] In some other embodiments, various sensors provided on the power module 300 can also monitor the real-time operation (status) data of the power module 300 in real time. The real-time operation (status) data of the power module 300 is transmitted to the control drive module 200 through the second connection module 520, so that the control drive module 200 can comprehensively consider the real-time operation (status) data of the power module 300 on the basis of the target operation data and the real-time operation data to generate a drive signal for controlling the target motor M.

[0066] The motor controller of this embodiment integrates the control drive module 200 on the substrate 100, and the vehicle controller 400 realizes signal interaction with the control drive module 200 through the first connection module 510, and the power module 300 realizes signal interaction with the control drive module 200 through the second connection module 520. On the one hand, the control function and drive function of the motor are integrated into the substrate 100, which can effectively improve the integration of the entire motor controller. At the same time, the transmission path of the drive signal can be shortened, which is conducive to reducing parasitic inductance; on the other hand, the setting of the first connection module 510 and the second connection module 520 enables the power module 300 to be plug-and-play. The first connection module 510 and the second connection module 520 are used to realize the split interconnection between the power module 300 and the control drive module 200, which can maintain the compactness of the structure and the integrity of the data during the operation of the vehicle, and can realize the welding-free and rapid disassembly and assembly of the power module 300 during the inspection, maintenance or bench test, which can effectively shorten the inspection, maintenance and test time, thereby reducing maintenance costs.

[0067] In one embodiment, Figure 3 As shown, the control drive module 200 includes a control unit 210 and a drive unit 220. The control unit 210 and the drive unit 220 are arranged on the same layer on the substrate 100. The control signal input end is formed on the control unit 210 so that the control unit 210 is electrically connected to the vehicle controller 400 through the first connection module 510. The drive signal output end is formed on the drive unit 220 so that the drive unit 220 is electrically connected to the power module 300 through the second connection module 520.

[0068] The control unit 210 is used to generate an intermediate signal for the power module 300 to control the target motor M based on the real-time operation data and target operation data of the target motor M; the drive unit 220 is used to generate a drive signal for the power module 300 to control the target motor M based on the intermediate signal.

[0069] The control unit 210 and the drive unit 220 are integrated on the substrate 100. In a specific implementation, the control unit 210 and the drive unit 220 can be partitioned into different areas on the substrate 100. For example, the substrate 100 can be divided into two areas: left and right, or two areas: upper and lower, or two areas: middle and inner. The control unit 210 and the drive unit 220 are respectively arranged in different areas to achieve the integration of the control unit 210 and the drive unit 220, while ensuring that the entire control and drive module 200 has functional partitioning. The control unit 210 and the drive unit 220 can also be cross-integrated and formed on the substrate 100. For example, the various components, chips, or structures in the control unit 210 and the drive unit 220 can be differentiated according to the voltage level of the signal, or according to the degree of anti-interference of the signal, dividing the substrate 100 into high-voltage and low-voltage areas. According to the influence of the integrated routing of the classified components, chips, and structures, the control unit 210 and the drive unit 220 are dispersed on the substrate 100 to take into account both signal anti-interference and transmission paths.

[0070] The control unit 210 has at least one control signal sub-input terminal, which forms the control signal input terminal for controlling the drive module 200. This allows the control unit 210 to be electrically connected to the target motor M and the vehicle controller 400 via the first connection module 510. Furthermore, the control unit 210 can receive status data of the target motor M and target operation data transmitted from the vehicle controller 400 through each control signal sub-input terminal. The drive unit 220 has at least one drive signal sub-output terminal, which forms the drive signal output terminal for controlling the drive module 200. This allows the drive unit 220 to be electrically connected to the power module 300 via the second connection module 520. Furthermore, the drive signal can be transmitted to the power module 300 through each drive signal sub-output terminal to drive the power module 300 to operate.

[0071] For example, the control unit 210 can obtain the real-time operating data of the target motor M and the target operating data for the target motor M sent by the vehicle controller 400. The control unit 210 can perform modulation based on the difference between the real-time operating data and the target operating data of the target motor M to generate an intermediate signal for the power module 300 to control the target motor M. The control unit 210 can transmit the intermediate signal to the drive unit 220 via the connection line between the control unit 210 and the drive unit 220. The drive unit 220 can perform PWM modulation on the intermediate signal to generate a drive signal for the power module 300 to control the target motor M.

[0072] In one embodiment, the control unit 210 includes a main control chip 211, a sampling circuit 212, a resolver circuit 213 and a bus circuit 214. The intermediate signal output end of the main control chip 211 is electrically connected to the intermediate signal input end of the driving unit 220. The sampling circuit 212, the resolver circuit 213 and the bus circuit 214 are electrically connected to the main control chip 211. The current sampling input end of the sampling circuit 212 is electrically connected to the power module 300 through the second connection module 520. The resolver signal input end of the resolver circuit 213 and the bus signal input end of the bus circuit 214 form the control signal input end of the control unit 210 and are electrically connected to the first connection module 510.

[0073] The sampling circuit 212 is used to collect the real-time current of the target motor M; the resolver circuit 213 is used to collect the real-time resolver signal of the target motor M; the bus circuit 214 is used to collect the target torque and target speed of the target motor M; the main control chip 211 is used to determine the real-time torque and real-time speed of the target motor M based on the real-time current and real-time resolver signal, and generate an intermediate signal for the power module 300 based on the real-time torque, real-time speed, target torque and target speed.

[0074] The sampling circuit 212 can accurately collect the real-time current signal of the target motor M during operation. In specific implementations, the sampling circuit 212 can be composed of various sensors (such as current transformers and Hall sensors), signal conditioning circuits (including amplification and filtering), and an analog-to-digital converter (ADC). The sensors can convert the current of the target motor M into a proportional voltage or current signal. The signal conditioning circuit can amplify and filter the voltage or current signal to eliminate noise and interference, and adjust the signal amplitude and range to meet the input requirements of the ADC. Finally, the ADC converts the conditioned analog signal into a digital signal and transmits it to the main control chip 211. The real-time current can be used to reflect information such as the load condition, power consumption, and whether there are any faults on the target motor M.

[0075] The resolver circuit 213 can collect the real-time resolver signal of the target motor M. The real-time resolver signal refers to the signal generated by the resolver sensor and related to the rotor rotation angle and speed of the target motor M. In a specific implementation, there is an electromagnetic coupling relationship between the stator and the rotor of the resolver sensor. When the rotor rotates, an AC voltage signal related to the rotor angle is induced in the stator winding. The AC voltage signal can be demodulated into a DC voltage signal or a digital signal. Thereafter, the rotation angle, direction, position and other information of the target motor M can be determined based on the demodulated DC voltage signal or digital signal. In some other embodiments, the resolver circuit 213 can also receive the sinusoidal excitation provided by the main control chip 211, and return the corresponding signal through the resolver sensor to feed back the target motor M reference signal to the main control chip 211, thereby obtaining the corresponding rotation angle, direction, position and other information.

[0076] The bus circuit 214 can realize data transmission between different devices or modules. In the electric drive system, the bus circuit 214 is mainly used to collect the target torque and target speed information of the target motor M. In specific implementation, the bus circuit 214 can be connected to the vehicle controller 400 and interact with the vehicle controller 400 through the corresponding bus protocol to obtain the target operating data determined by the vehicle controller 400 based on the real-time operating conditions of the target motor M, namely the target torque and target speed, etc. In some other embodiments, the bus circuit 214 can also return the operating status through the CAN FD (CAN with Flexible Data rate, variable rate CAN bus) high-speed link to ensure millisecond-level synchronization of the control closed loop.

[0077] The main control chip 211 can be implemented using a microcontroller unit (MCU) or a digital signal processor (DSP). The main control chip 211 can determine the real-time speed and torque of the target motor M based on the real-time current of the target motor M collected by the sampling circuit 212 and the real-time resolver signal of the target motor M collected by the resolver circuit 213 (such as the rotor rotation direction, position, and angle of the target motor M). This can then be compared with the target speed and target torque obtained by the bus circuit 214 to generate an intermediate signal.

[0078] For example, when controlling the target motor M, a current sensor provided on the target motor M can monitor the real-time current of the target motor M. The sampling circuit 212 can obtain the real-time current monitored by the current sensor and transmit it to the main control chip 211. Simultaneously, the resolver sensor in the resolver circuit 213 can monitor the rotor position and direction of the target motor M in real time and transmit these data to the main control chip 211. The main control chip 211 can determine the real-time speed and torque of the target motor M based on the real-time current of the target electrode and the rotor position and direction (i.e., real-time resolver data). The bus circuit 214 can obtain the target torque and target speed of the target motor M transmitted by the vehicle controller and transmit them to the main control chip 211. The main control chip 211 can determine the voltage or current value (i.e., the intermediate signal) for controlling the target motor M based on the difference between the real-time speed and the target speed, and between the real-time torque and the target torque.

[0079] In one embodiment, the control unit 210 further includes a fault detection circuit 215 electrically connected to the main control chip 211 , and a fault signal input terminal of the fault detection circuit 215 is electrically connected to the power module 300 through the second connection module 520 .

[0080] The fault detection circuit 215 is used to collect fault data of the power module 300; the sampling circuit 212 is also used to collect the first state data of the target motor M and the second state data of the power module 300; the main control chip 211 is also used to generate monitoring data for monitoring the operating status of the target motor M based on real-time current, fault data, first state data and second state data.

[0081] Fault data refers to data that reflects abnormalities or faults occurring in the IGBTs (Insulated Gate Bipolar Transistor) within the power module 300. Fault data can be used to record various fault characteristics that occur during IGBT operation. In specific implementations, IGBT fault data can be collected by the fault detection circuit 215. The fault detection circuit 215 can include multiple detection elements and modules, such as an overcurrent detection module, an overvoltage detection module, and an overheating detection module, to monitor IGBT parameters such as current, voltage, and temperature in real time. When a parameter exceeds a normal range, a corresponding fault signal is triggered, which is converted into a digital or analog signal by the fault detection circuit 215 and transmitted to the main control chip 211. First state data refers to state data of the target motor M during real-time operation, including but not limited to voltage and current data on the DC bus of the target motor M. Second state data refers to state data of the power module 300 during real-time operation, including but not limited to operating temperature and operating current of the IGBTs within the power module 300. Monitoring data refers to a set of data generated by the main control chip 211 after comprehensive analysis and processing based on the real-time current, fault data, first state data, and second state data. Monitoring data can be used to monitor the operation of the system in real time, so as to detect potential problems and anomalies in a timely manner.

[0082] Exemplarily, the fault detection circuit 215 collects the current, voltage, and temperature of the IGBT in the power module 300 through various detection modules, compares the current, voltage, and temperature data with their corresponding thresholds, and generates IGBT fault data and transmits it to the main control chip 211 when the current, voltage, and temperature exceed the corresponding thresholds. The main control chip 211 can then control the on and off of the IGBT based on the fault data to prevent the IGBT from outputting motor control signals to the target motor M in the event of a fault. In addition, the sampling circuit 212 can also collect voltage and current data on the DC bus of the target motor M through various sensors installed in the target motor M and circuits, and collect data such as the operating temperature and operating current of the IGBT through various sensors installed in corresponding positions in the power module 300. The sampling circuit 212 can transmit the voltage and current data on the DC bus, the operating temperature, and the operating current to the main control chip 211 to generate corresponding monitoring data, which is then transmitted to the host computer via the bus circuit 214, so that the host computer can monitor the operating status of the target motor M and the power module in real time.

[0083] In one embodiment, the control and drive module 200 further includes a power supply circuit 216 connected to the control unit 210 and the drive unit 220. The input end of the power supply circuit 216 is connected to the vehicle's battery, and the output end of the power supply circuit 216 is electrically connected to the control unit 210 and the drive unit 220, respectively, to provide power to the control unit 210 and the drive power supply. The power supply circuit 216 can step down the voltage output by the battery and provide it to the control unit 210 and the drive unit 220, respectively. In a specific implementation, the power supply circuit 216 can step down the voltage according to the corresponding operating voltage of the control unit 210 and the drive unit 220, to ensure the safe and stable operation of the control unit 210 and the drive unit 220.

[0084] In an optional embodiment, the first connection module 510 can be connected to the bus of the vehicle controller 400 to power the various modules on the substrate 100 through the battery; and the motor temperature signal and the real-time current of the motor collected by the sampling circuit 212, the resolver excitation and real-time resolver signal collected by the resolver circuit 213, and the target operation data of the bus circuit 214 can all be transmitted to the main control chip 211 through the first connection module 510.

[0085] In one embodiment, the second connection module 520 includes a first drive connector and a second drive connector. The first drive connector and the second drive connector can be implemented using high-shield quick-connect connectors. The first drive connector and the second drive connector are both integrated on the substrate 100 to facilitate quick disassembly and assembly of the power module and the drive unit 220.

[0086] Further, such as Figure 4 As shown, the power module 300 includes at least one transformer circuit 310 and at least one inverter circuit 320, and the transformer circuit 310 and the inverter circuit 320 are arranged in a one-to-one correspondence. The transformer circuit 310 is electrically connected to the first drive signal output terminal of the drive unit 220 through a first drive connector, the voltage signal input terminal of the transformer circuit 310 is connected to an external power supply, the voltage signal output terminal of the transformer circuit 310 is electrically connected to the voltage input terminal of the inverter circuit 320, and the inverter circuit 320 is electrically connected to the second drive signal output terminal of the drive unit 220 through a second drive connector.

[0087] The transformer circuit 310 is used to dynamically adjust the power supply voltage of the external power supply input according to the transformer drive signal to obtain a DC drive voltage that matches the voltage level of the inverter circuit 320; the inverter circuit 320 is used to invert the DC drive voltage according to the inverter drive signal to obtain an AC control voltage for controlling the target motor M.

[0088] The drive signal includes a transformer drive signal and an inverter drive signal. The transformer drive signal is used to drive the transformer circuit 310 to operate. The transformer drive signal can be transmitted from the drive unit 220 to the transformer circuit 310 through the first drive connector to provide a drive voltage for the transformer circuit 310, so that the transformer circuit 310 can operate in a suitable transformer mode and obtain a DC drive voltage that matches the voltage level of the subsequent inverter circuit 320. The inverter drive signal is used to drive the inverter circuit 320 to operate. The inverter drive signal can be transmitted from the drive unit 220 to the inverter circuit 320 through the second drive connector to provide a drive voltage for the inverter circuit 320, so that the inverter circuit 320 can invert the DC drive voltage to obtain an AC control voltage.

[0089] The first drive signal output terminal of the drive unit 220 is used to output a voltage-variable drive signal, and the voltage signal input terminal of the voltage-variable circuit 310 is connected to an external power source. In a specific implementation, a DC power strip can be provided on the substrate 100, and the external power source and the voltage-variable circuit 310 can be connected via the DC power strip. This allows the voltage-variable circuit 310, driven by the voltage-variable drive signal, to step up or down the power supply voltage input by the external power source to obtain a DC drive voltage that matches the voltage level of the inverter circuit 320. Matching the voltage level of the inverter circuit 320 means matching the voltage corresponding to the motor control signal output by the inverter circuit 320 to the target motor M. After the DC drive voltage is inverted by the inverter circuit 320, the resulting AC control voltage can control the operation of the target motor M to achieve the target operating state. The voltage signal output terminal of the voltage-variable circuit 310 is electrically connected to the voltage input terminal of the inverter circuit 320 to output the DC drive voltage to the inverter circuit 320.

[0090] Depending on the number of controlled motors corresponding to the motor controller, a corresponding number of inverter circuits 320 can be provided in the power module 300. For example, when the controlled motors include a drive motor and a generator, two inverter circuits 320 can be provided. One inverter circuit 320 is connected to the drive motor via a three-phase socket outlet to provide a motor control signal (i.e., an AC control voltage) to the drive motor. The other inverter circuit 320 is connected to the generator via another three-phase socket outlet to provide a motor control signal to the generator. The motor controller can control at least one motor. To control different controlled motors, the drive unit 220 can send inverter drive signals to different inverter circuits 320 to drive the corresponding inverter circuits 320 to operate. Correspondingly, according to the number of inverter circuits 320, corresponding second drive connectors can be set, so that each inverter circuit 320 can be connected to the second drive signal output of the drive unit 220 through its corresponding second drive connector to access its corresponding inverter drive signal, thereby enabling the inverter circuit 320 to invert the DC drive voltage transmitted by the transformer circuit 310 under the driving action of its corresponding inverter drive signal to obtain a corresponding AC control voltage.

[0091] For example, the main control chip 211 can determine the voltage conversion mode of the voltage conversion circuit 310, i.e., boost or buck, based on the power supply voltage output by the external power supply (typically a battery). When boosting, the voltage conversion circuit 310 can convert the power supply voltage into a DC drive voltage and provide it to the inverter circuit 320. When bucking, the voltage conversion circuit 310 can drive the inverter circuit 320 to reversely feed power to the battery via the target motor M. Taking the voltage conversion circuit 310 operating in boost mode as an example, the voltage conversion circuit 310 can dynamically adjust the power supply voltage input by the external power supply based on the voltage conversion drive signal output by the drive unit 220, obtain a DC drive voltage that matches the voltage level of the inverter circuit 320, and transmit it to the inverter circuit 320. The inverter circuit 320 can receive the DC drive voltage and invert it based on the inverter drive signal output by the drive unit 220 to obtain an AC control voltage for controlling the target motor M.

[0092] In one embodiment, the voltage conversion driving signal is a PWM signal with a variable duty cycle. The driving unit 220 can convert the power supply voltage input to the voltage conversion circuit 310 into a DC driving voltage output with adjustable amplitude by modulating the PWM signal.

[0093] The voltage conversion circuit 310 includes a first capacitor C1, a second capacitor C2, a reactor L, a first voltage conversion transistor VCU-H, and a second voltage conversion transistor VCU-L. Specifically, the first end of the first capacitor C1 is connected to the positive electrode of the external power supply, and the second end of the first capacitor C1 is connected to the negative electrode of the external power supply. The first end of the first capacitor C1 is also electrically connected to the emitter of the first voltage conversion transistor VCU-H and the collector of the second voltage conversion transistor VCU-L through the reactor L. The collector of the first voltage conversion transistor VCU-H is electrically connected to the first end of the second capacitor C2, and the second end of the second capacitor C2 is electrically connected to the second end of the first capacitor C1 and the emitter of the second voltage conversion transistor VCU-L. The gates of the first voltage conversion transistor VCU-H and the second voltage conversion transistor VCU-L are electrically connected to the first drive signal output terminal of the drive unit 220 via the first drive connector. The first and second ends of the second capacitor C2 form the voltage signal output terminal of the voltage conversion circuit 310 and are electrically connected to the voltage input terminal of the inverter circuit 320.

[0094] The gate of the first voltage-converting transistor VCU-H and the gate of the second voltage-converting transistor VCU-L can be used to receive the voltage-converting drive signal transmitted by the drive unit 220, so as to control the conduction and shutoff of the current in each loop of the voltage-converting circuit 310 by turning on or off under the control of the voltage-converting drive signal. In specific implementation, the first voltage-converting transistor VCU-H and the second voltage-converting transistor VCU-L can be implemented using switching transistors, such as triodes, MOSFETs (Metal-Oxide-Semiconductor Field-Effect Transistors), IGBTs, etc. The inductor L can convert electrical energy into magnetic energy for storage, and can also convert magnetic energy into electrical energy for release again. The first capacitor C1 and the second capacitor C2 can discharge when the voltage across the capacitors is higher than the voltage of the external circuit, and can charge when the voltage across the capacitors is higher than the voltage of the external circuit.

[0095] Exemplarily, when the voltage conversion circuit 310 operates in the boost mode, the voltage conversion circuit 310 can boost the power supply voltage of 260V to 650V. Specifically, the voltage conversion drive signal is connected to the gate of the first voltage conversion transistor VCU-H and the gate of the second voltage conversion transistor VCU-L, so that the first voltage conversion transistor VCU-H is cut off and the second voltage conversion transistor VCU-L is turned on. At this time, the power supply voltage charges the inductor L, so that energy is accumulated on the inductor L. Thereafter, the drive unit 220 can control the first voltage conversion transistor VCU-H and the second voltage conversion transistor VCU-L to be cut off through the voltage conversion drive signal, so that the energy accumulated on the inductor L and the energy of the power supply voltage are simultaneously provided to the inverter circuit 320 through the diode in the first voltage conversion transistor VCU-H. When the voltage conversion circuit 310 operates in the step-down mode, the voltage conversion circuit 310 can reduce the voltage of 650V on the target motor M side to 260V. Specifically, the voltage conversion drive signal is connected to the gate of the first voltage conversion transistor VCU-H and the gate of the second voltage conversion transistor VCU-L, so that the first voltage conversion transistor VCU-H is turned on and the second voltage conversion transistor VCU-L is turned off. At this time, the power supply voltage on the target motor M side charges the inductor L, so that energy is accumulated on the inductor L. Thereafter, the drive unit 220 can control the first voltage conversion transistor VCU-H and the second voltage conversion transistor VCU-L to be turned off through the voltage conversion drive signal, so that the energy accumulated on the inductor L is fed to the external power supply through the diode in the second voltage conversion transistor VCU-L.

[0096] In an optional embodiment, the voltage signal output end of the transformer circuit 310 has a step-down end and a step-up end, wherein the step-down end is formed at an end of the transformer circuit 310 close to the external power supply, and the step-down end has a positive input end and a negative input end; the step-up end is formed at an end of the transformer circuit 310 close to the inverter circuit 320, and the step-up end has a positive output end and a negative output end; a first voltage sensor V1 is provided at the positive input end, and a second voltage sensor V2 is provided at the positive output end to monitor the DC drive voltages of the step-down end and the step-up end in the transformer circuit 310 in real time; in addition, a first current sensor VCU can also be provided between the inductor L and the emitter of the first transformer transistor VCU-H (that is, the collector of the second transformer transistor VCU-L) to monitor the current in the loop in real time. In specific implementation, the first voltage sensor V1, the second voltage sensor V2 and the first current sensor VCU can be connected to the second connection module 520 through a printed circuit. Correspondingly, corresponding pin leads can be set on the power module 300 and connected to the corresponding pins or pins of the second connection module 520 to connect the first voltage sensor V1, the second voltage sensor V2 and the first current sensor VCU to the corresponding positions of the transformer circuit 310.

[0097] In one embodiment, the inverter circuit 320 includes a first high-voltage transistor UH, a second high-voltage transistor VH, a third high-voltage transistor WH, a first low-voltage transistor UL, a second low-voltage transistor VL, and a third low-voltage transistor WL. Specifically, the gate of the first high-voltage transistor UH, the gate of the second high-voltage transistor VH, the gate of the third high-voltage transistor WH, the gate of the first low-voltage transistor UL, the gate of the second low-voltage transistor VL and the gate of the third low-voltage transistor WL are electrically connected to the second drive signal output end of the drive unit 220 through the second drive connector; the collector of the first high-voltage transistor UH and the emitter of the first low-voltage transistor UL are connected to the DC drive voltage, the emitter of the first high-voltage transistor UH is connected to the collector of the first low-voltage transistor UL and outputs the first phase voltage, the collector of the second high-voltage transistor VH and the emitter of the second low-voltage transistor VL are connected to the DC drive voltage, the emitter of the second high-voltage transistor VH is connected to the collector of the second low-voltage transistor VL and outputs the second phase voltage, the collector of the third high-voltage transistor WH and the emitter of the third low-voltage transistor WL are connected to the DC drive voltage, the emitter of the third high-voltage transistor WH is connected to the collector of the third low-voltage transistor WL and outputs the third phase voltage.

[0098] Among them, the first high-voltage transistor UH, the second high-voltage transistor VH, the third high-voltage transistor WH, the first low-voltage transistor UL, the second low-voltage transistor VL, and the third low-voltage transistor WL can be implemented using IGBTs. The number of pins of the second drive connector can be designed according to the connection requirements of the gates of each transistor to ensure that the gate of each transistor can be accurately connected to the corresponding drive signal output terminal of the drive unit 220. In specific implementation, the inverter drive signal generated by the drive unit 220 can control the conduction and shutdown of each transistor. Parameters such as the waveform, frequency, and duty cycle of the inverter drive signal can be adjusted according to the operating requirements of the inverter circuit 320.

[0099] Among the six transistors, the high-voltage transistor and the low-voltage transistor in the same branch are grouped together to form a phase branch. For example, the first high-voltage transistor UH is connected to the first low-voltage transistor UL to form a first phase branch, which is used to output a first phase voltage based on the DC drive voltage under the action of a corresponding inverter drive signal. For example, the second high-voltage transistor VH is connected to the second low-voltage transistor VL to form a second phase branch, which is used to output a second phase voltage based on the DC drive voltage under the action of a corresponding inverter drive signal. The third high-voltage transistor WH is connected to the third low-voltage transistor WL to form a third phase branch, which is used to output a third phase voltage based on the DC drive voltage under the action of a corresponding inverter drive signal.

[0100] The collector of the first high-voltage transistor UH and the emitter of the first low-voltage transistor UL are connected to a DC drive voltage. The emitter of the first high-voltage transistor UH is connected to the collector of the first low-voltage transistor UL. This connection point serves as the output terminal for the first phase voltage and is connected to the U-phase winding of the target motor M. When the first high-voltage transistor UH is on and the first low-voltage transistor UL is off, the first phase voltage output approaches the positive potential of the DC drive voltage. When the first high-voltage transistor UH is off and the first low-voltage transistor UL is on, the first phase voltage output approaches the negative potential of the DC drive voltage. By properly controlling the on and off times of the two transistors, an AC voltage with a certain frequency and amplitude can be generated at the first phase voltage output terminal.

[0101] The collector of the second high-voltage transistor VH and the emitter of the second low-voltage transistor VL are also connected to the DC drive voltage, and the connection method is the same as the first phase branch. The emitter of the second high-voltage transistor VH is connected to the collector of the second low-voltage transistor VL, and this connection point is connected to the V-phase winding of the target motor M as the output end of the second phase voltage. The output principle of the second phase voltage is similar to that of the first phase voltage, but in order to obtain three-phase alternating current, the phase of the second phase voltage differs by 120° from that of the first phase voltage. This can be achieved by performing corresponding phase delay control on the inverter drive signal output by the drive unit 220 to the second high-voltage transistor VH and the second low-voltage transistor VL.

[0102] The collector of the third high-voltage transistor WH and the emitter of the third low-voltage transistor WL are connected to the DC drive voltage in the same manner as the first phase branch. The emitter of the third high-voltage transistor WH is connected to the collector of the third low-voltage transistor WL. This connection serves as the output terminal for the third-phase voltage and is connected to the W-phase winding of the target motor M. The third-phase voltage is 240° out of phase with the first-phase voltage (or 120° out of phase with the second-phase voltage). Similarly, the drive unit 220 controls the inverter drive signals of the corresponding transistors to ensure the correct phase relationship of the three-phase AC power.

[0103] In an optional embodiment, second current sensors CT1 and CT2 are further provided on the branches outputting each phase voltage of the inverter circuit 320 to monitor in real time the current (i.e., the IGBT current) outputted by the inverter circuit 320 to the target motor M. In a specific implementation, the second current sensors CT1 and CT2 can be connected to the second connection module 520 via a printed circuit board. Corresponding pins can be provided on the power module 300 and connected to corresponding pins or pins of the second connection module 520, thereby connecting the second current sensors CT1 and CT2 to corresponding positions of the transformer circuit 310.

[0104] In an optional embodiment, the first drive connector and the second drive connector can also be integrated on the same connector, that is, the second connection module 520 can be connected to the transformer circuit 310 and the inverter circuit 320 as a whole, so as to be connected to the gate of the first transformer transistor VCU-H and the gate of the second transformer transistor VCU-L in the transformer circuit 310 through different connection channels, and to the gate of the first high-voltage transistor UH, the gate of the second high-voltage transistor VH, the gate of the third high-voltage transistor WH, the gate of the first low-voltage transistor UL, the gate of the second low-voltage transistor VL and the gate of the third low-voltage transistor WL in the inverter circuit 320, so as to input corresponding drive signals into the transformer circuit 310 and the inverter circuit 320. In specific implementation, when multiple motors are set, taking the setting of two motors (including a generator and a drive motor) as an example, two groups of first drive connectors and second drive connectors can be set on the substrate 100, or two second connection modules 520 integrating the first drive connector and the second drive connector can be set. Each second connection module 520 is correspondingly connected to a group of transformer circuits 310 and inverter circuits 320, that is, each second connection module 520 is connected to the gates of the transistors in the corresponding transformer circuits 310 and inverter circuits 320 through different channels, and the emitters and collectors of the transistors between different transformer circuits 310 and inverter circuits 320 are connected in parallel, so that the control drive module 200 can independently control each motor through the corresponding second connection module 520, or can control multiple motors at the same time.

[0105] In one embodiment, the substrate 100 has a high-voltage area and a low-voltage area. The high-voltage area is formed at the edge of the substrate 100, and the low-voltage area is located on the inner side of the high-voltage area. The second connection module 520 and the driving unit 220 and the sampling circuit 212 in the control drive module 200 are arranged in the high-voltage area, and the first connection module 510 and the main control chip 211, bus circuit 214, resolver circuit 213 and fault detection circuit 215 in the control drive module 200 are arranged in the low-voltage area.

[0106] Among them, dividing the substrate 100 into a high-voltage area and a low-voltage area can achieve electrical isolation between high-voltage components and low-voltage components, and reduce the interference of high-voltage signals on low-voltage signals. In specific implementation, an "L-shaped split" layout can be adopted between the high-voltage area and the low-voltage area, that is, the high-voltage area can extend along two adjacent edges of the substrate 100. For example, if the substrate 100 is rectangular, the high-voltage area can be divided along a part of the long side and the wide side to form an "L" shape. The low-voltage area is located on the inside of the high-voltage area, occupying most of the middle area of ​​the substrate 100, ensuring that the power path is shortest and the control signal return area is minimized, and the edge space of the substrate 100 can be fully utilized to arrange high-voltage components and provide a relatively independent electrical environment for low-voltage components.

[0107] In an optional embodiment, the second connection module 520 is isolated from the first connection module 510 during arrangement. In the second connection module 520, the first drive connector is connected to the transformer circuit 310, and the second drive connector is connected to the inverter circuit 320. In the inverter circuit 320, one inverter circuit 320 and one target motor M are grouped together. The drive resistor in the inverter circuit 320 can be set close to the pin of the second drive connector, and the wiring can be arranged in a "short-thick-symmetrical" manner. In the short wiring method, the shorter the wiring length, the shorter the signal transmission path, and the less attenuation and interference of the signal during transmission. At the same time, the short wiring can reduce the space on the substrate 100 occupied by the wiring, which is conducive to improving the integration of the substrate 100. In specific implementation, the relevant components can be arranged as close as possible to reduce the length of the connecting wiring between the components. For example, in the high-voltage area, the drive unit 220 is arranged close to the IGBT to make the drive signal wiring as short as possible. In a thick trace routing scheme, the thicker the trace, the lower its resistance, the greater the current it can carry, and the relatively lower its inductance. For high-current signals or signals with low impedance requirements, using thick traces can reduce signal loss and voltage drop, improving signal stability and reliability. In specific implementations, the appropriate trace width can be determined based on the signal current and impedance requirements. Symmetrical traces can offset interference encountered during signal transmission, reducing signal distortion and distortion. Especially for differential signals, symmetrical traces can ensure differential signal balance and improve signal interference resistance. Furthermore, each transistor in inverter circuit 320 has five connection terminals: A (anode), K (cathode), G (gate), KE (Kelvin emitter), and SE (current sensor). The anode and cathode serve as electrodes of a temperature-sensing diode, and the potential difference between the anode and cathode can be used to determine the transistor's temperature. The gate, as the transistor's control terminal, can receive an inverter drive signal (such as OFF / ON) to turn the transistor on and off. The Kelvin emitter can be used to measure the emitter potential. A current sensor can shunt and detect the emitter current for overcurrent protection. For transistor wiring, differential routing can be used for the gate trigger line and the emitter (Kelvin emitter) line to reduce common-mode interference.

[0108] In an optional embodiment, the drive unit 220 and control unit 210 are integrated on the substrate 100 to form an integrated control and drive module 200. The drive signals corresponding to the gates of each transistor are directly supplied by the drive unit 220 via a battery, eliminating the boost DC / DC link in traditional solutions. This shortens the drive loop, reduces parasitic inductance, and improves gate drive strength and anti-interference margin, achieving dual optimization of cost and volume while ensuring reliability.

[0109] In one embodiment, an electric drive system is provided, comprising the motor controller of each of the above embodiments; in addition, the electric drive system may further comprise at least one controlled motor, wherein the at least one controlled motor is connected to the motor controller. Specifically, the power module 300 has motor control output terminals corresponding one to each controlled motor, each controlled motor being connected to the motor control output terminals. The motor control signals generated by the power module 300 may be connected to each controlled motor via the motor control output terminals to control each controlled motor.

[0110] In one embodiment, Figure 5 As shown, a control method for a motor controller is provided. The control method can be applied to the motor controller described in the above embodiment. The method of this embodiment includes the following steps 502 to 506, wherein:

[0111] Step 502 : Acquire real-time operating data and target operating data of the target motor M.

[0112] Among them, the target motor M refers to the motor that needs to be controlled and monitored in the electric drive system. The target motor M can be various types of motors, such as a drive motor, a generator, etc., depending on the application scenario. For example, it may be a drive motor in an electric vehicle, and it may be a motor used to drive a robotic arm or a conveyor belt in industrial automation. Real-time operation data refers to the data of the target motor M during the actual operation process, which can be used to reflect the actual operating status of the target motor M. The real-time operation data may include but is not limited to the real-time current, real-time voltage, real-time speed, real-time torque, real-time steering and real-time steering angle of the target motor M. The target operation data refers to the operating state that the target motor M needs to achieve based on the operating conditions of the target motor M. The target operation data may include but is not limited to the target speed, target torque, target steering and target steering angle.

[0113] Step 504 : Determine a driving signal for the power module 300 to control the target motor M based on the real-time operating data and the target operating data.

[0114] Among them, the driving signal refers to the driving force (or voltage) required by the power module 300 when outputting the corresponding motor control signal when the target motor M reaches the target operating state based on the real-time operating data and the target operating data; the driving signal can be a PWM signal after adjustment.

[0115] Step 506 : Generate a motor control signal for the target motor M according to the driving signal to control the target motor M.

[0116] Among them, the motor control signal refers to the control voltage required when the target motor M reaches the target operating state from the current operating state (real-time operating state). The motor control signal can be obtained by inverting the external power supply through the power module 300 under the driving action of the driving signal.

[0117] In specific implementation, the process in which the motor controller obtains the real-time operating data and target operating data of the target motor M and determines the motor control signal for the target motor M based on the real-time operating data and target operating data can be referred to the relevant records in the above embodiment and will not be repeated here.

[0118] In an application example, Figure 6 As shown, the vehicle controller 400 can determine the target torque and target speed for the target motor M based on the engine operating conditions. The actuator determines the actual torque and actual speed of the target motor M based on the real-time current and steering angle of the target motor M. The motor controller can subtract the target torque from the actual torque to obtain a torque difference, and subtract the target speed from the actual speed to obtain a speed difference. The motor controller can then generate an intermediate signal based on the torque difference and speed difference, as well as the three-phase current of the target motor M, IGBT status data (operating temperature, current, etc.) collected by the actuator, and the actual steering direction of the target motor M. The electrode controller can use SVPWM modulation on the intermediate signal to generate a PWM signal (i.e., a drive signal) and output the PWM signal to the gate of each IGBT, which is then transmitted to the inverter circuit 320. The inverter circuit 320 inverts the DC drive signal into an AC control signal, thereby controlling the torque and speed of the target motor M.

[0119] It should be understood that, although the various steps in the flowcharts involved in the various embodiments described above are displayed in sequence according to the instructions of the arrows, these steps are not necessarily executed in sequence in the order indicated by the arrows. Unless otherwise specified herein, there is no strict order restriction on the execution of these steps, and these steps can be executed in other orders. Moreover, at least a portion of the steps in the flowcharts involved in the various embodiments described above can include multiple steps or multiple stages, and these steps or stages are not necessarily executed and completed at the same time, but can be executed at different times, and the execution order of these steps or stages is not necessarily to be carried out in sequence, but can be executed in turn or alternately with other steps or at least a portion of steps or stages in other steps.

[0120] In the description of this specification, reference to the terms "some embodiments" or "other embodiments" means that the specific features, structures, materials, or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. In this specification, the schematic descriptions of the above terms do not necessarily refer to the same embodiment or example.

[0121] The technical features of the above-mentioned embodiments can be combined arbitrarily. In order to make the description concise, not all possible combinations of the technical features in the above-mentioned embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0122] The above-described embodiments merely represent several implementation methods of the present application. While the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the present application. It should be noted that a person of ordinary skill in the art may make various modifications and improvements without departing from the spirit of the present application, and these modifications and improvements fall within the scope of protection of the present application. Therefore, the scope of protection of the present application shall be determined by the appended claims.

Claims

1. A motor controller, characterized in that: The vehicle control module comprises a substrate, a control drive module, and a power module. The control drive module is arranged on the substrate. A first connection module and a second connection module are arranged on the substrate. The first signal input end of the first connection module is electrically connected to the control signal output end of the vehicle controller, the first signal output end of the first connection module is electrically connected to the control signal input end of the control drive module, the second signal input end of the second connection module is electrically connected to the drive signal output end of the control drive module, and the second signal output end of the second connection module is electrically connected to the drive signal input end of the power module. The control drive module is used to determine the drive signal for the power module to control the target motor according to the real-time operation data and target operation data of the target motor; The power module is used to generate a motor control signal for the target motor according to the driving signal, so as to control the target motor.

2. The motor controller according to claim 1, characterized in that: The control drive module includes a control unit and a drive unit, the control unit and the drive unit are arranged on the same layer on the substrate, the control signal input end is formed on the control unit so that the control unit is electrically connected to the vehicle controller through the first connection module, and the drive signal output end is formed on the drive unit so that the drive unit is electrically connected to the power module through the second connection module; The control unit is configured to generate an intermediate signal for the power module to control the target motor according to the real-time operating data and target operating data of the target motor; The driving unit is configured to generate a driving signal for the power module to control the target motor according to the intermediate signal.

3. The motor controller according to claim 2, characterized in that: The control unit includes a main control chip, a sampling circuit, a resolver circuit, and a bus circuit. The intermediate signal output terminal of the main control chip is electrically connected to the intermediate signal input terminal of the drive unit. The sampling circuit, the resolver circuit, and the bus circuit are electrically connected to the main control chip. The current sampling input terminal of the sampling circuit is electrically connected to the power module via the second connection module. The resolver signal input terminal of the resolver circuit and the bus signal input terminal of the bus circuit form a control signal input terminal of the control unit and are electrically connected to the first connection module. The sampling circuit is used to collect the real-time current of the target motor; The resolver circuit is used to collect the real-time resolver signal of the target motor; The bus circuit is used to collect the target torque and target speed of the target motor; The main control chip is used to determine the real-time torque and real-time speed of the target motor based on the real-time current and the real-time resolver signal, and to generate an intermediate signal for the power module to control the target motor based on the real-time torque, the real-time speed, the target torque and the target speed.

4. The motor controller according to claim 3, characterized in that: The control unit further includes a fault detection circuit electrically connected to the main control chip, and a fault signal input end of the fault detection circuit is electrically connected to the power module through the second connection module; The fault detection circuit is used to collect fault data of the power module; The sampling circuit is further used to collect the first state data of the target motor and the second state data of the power module; The main control chip is further configured to generate monitoring data for monitoring the operating state of the target motor according to the real-time current, the fault data, the first state data, and the second state data.

5. The motor controller according to claim 2, characterized in that: The second connection module includes a first drive connector and a second drive connector; the drive signal includes a voltage-converting drive signal and an inverting drive signal; The power module includes at least one transformer circuit and at least one inverter circuit, and the transformer circuit and the inverter circuit are arranged in a one-to-one correspondence. The transformer circuit is electrically connected to the first drive signal output terminal of the drive unit through the first drive connector, the voltage signal input terminal of the transformer circuit is connected to an external power supply, the voltage signal output terminal of the transformer circuit is electrically connected to the voltage input terminal of the inverter circuit, and the inverter circuit is electrically connected to the second drive signal output terminal of the drive unit through the second drive connector; The voltage conversion circuit is used to dynamically adjust the power supply voltage input by the external power supply according to the voltage conversion drive signal to obtain a DC drive voltage that matches the voltage level of the inverter circuit; The inverter circuit is used to invert the DC drive voltage according to the inverter drive signal to obtain an AC control voltage for controlling the target motor.

6. The motor controller according to claim 5, characterized in that: The voltage conversion circuit includes a first capacitor, a second capacitor, an inductor, a first voltage conversion transistor and a second voltage conversion transistor. The first end of the first capacitor is connected to the positive electrode of the external power supply, and the second end of the first capacitor is connected to the negative electrode of the external power supply. The first end of the first capacitor is also electrically connected to the emitter of the first voltage conversion transistor and the collector of the second voltage conversion transistor through the inductor. The collector of the first voltage conversion transistor is electrically connected to the first end of the second capacitor, and the second end of the second capacitor is electrically connected to the second end of the first capacitor and the emitter of the second voltage conversion transistor. The gate of the first voltage conversion transistor and the gate of the second voltage conversion transistor are electrically connected to the first drive signal output end of the drive unit through the first drive connector. The first end and the second end of the second capacitor form the voltage signal output end of the voltage conversion circuit and are electrically connected to the voltage input end of the inverter circuit.

7. The motor controller according to claim 5, characterized in that: The inverter circuit includes a first high-voltage transistor, a second high-voltage transistor, a third high-voltage transistor, a first low-voltage transistor, a second low-voltage transistor and a third low-voltage transistor; the gate of the first high-voltage transistor, the gate of the second high-voltage transistor, the gate of the third high-voltage transistor, the gate of the first low-voltage transistor, the gate of the second low-voltage transistor and the gate of the third low-voltage transistor are electrically connected to the second drive signal output end of the drive unit through the second drive connector; the collector of the first high-voltage transistor and the emitter of the first low-voltage transistor are connected to the DC drive voltage, the emitter of the first high-voltage transistor is connected to the collector of the first low-voltage transistor and outputs the first phase voltage, the collector of the second high-voltage transistor and the emitter of the second low-voltage transistor are connected to the DC drive voltage, the emitter of the second high-voltage transistor is connected to the collector of the second low-voltage transistor and outputs the second phase voltage, the collector of the third high-voltage transistor and the emitter of the third low-voltage transistor are connected to the DC drive voltage, the emitter of the third high-voltage transistor is connected to the collector of the third low-voltage transistor and outputs the third phase voltage.

8. The motor controller according to any one of claims 1 to 7, characterized in that: The substrate has a high-voltage area and a low-voltage area, the high-voltage area is formed at the edge of the substrate, and the low-voltage area is located inside the high-voltage area. The second connection module and the drive unit and sampling circuit in the control drive module are arranged in the high-voltage area, and the first connection module and the main control chip, bus circuit, resolver circuit and fault detection circuit in the control drive module are arranged in the low-voltage area.

9. A control method for a motor controller, characterized in that: Applied to the motor controller according to any one of claims 1 to 8, the method comprises the following steps: Acquire real-time operating data and target operating data of the target motor; Determining a drive signal for the power module to control a target motor according to the real-time operating data and the target operating data; A motor control signal for the target motor is generated according to the drive signal to control the target motor.

10. An electric drive system, characterized in that: The motor controller comprises the motor controller according to any one of claims 1 to 8.

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