Power module, motor controller, electric drive assembly and vehicle

Abstract

The invention discloses a power module, a motor controller, an electric drive assembly and a vehicle, the power module comprises a plurality of sub-power modules, each sub-power module corresponds to one phase, and at least two sub-power modules share the same pair of positive terminal and negative terminal. The structural design of the power module is beneficial to reducing the occupied volume and lowering the cost.

Description

Technical Field

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

[0002] The power module is a key component of the motor controller in new energy vehicles. In related technologies, a power module consists of multiple sub-power modules, each corresponding to a phase. Each sub-power module has a pair of positive and negative terminals, an AC terminal, and a separate liner. Integrating and packaging multiple sub-power modules to form a power module requires a large footprint and is costly. Reducing the cost and size of power modules has long been a major industry pursuit. Summary of the Invention

[0003] The purpose of this application is to provide a power module, a motor controller, an electric drive assembly and a vehicle, wherein the structural design of the power module is conducive to reducing the occupied volume and lowering the cost.

[0004] To solve the above technical problems, an embodiment of the present application provides a power module, including multiple sub-power modules, each of which corresponds to a phase, and at least two of the sub-power modules share the same pair of positive terminals and negative terminals.

[0005] In one feasible solution, the at least two sub-power modules share a liner.

[0006] In one feasible solution, at least two sub-power modules among the plurality of sub-power modules share a common liner.

[0007] In one feasible solution, the power module includes a drive control module and a power generation control module; the drive control module includes at least one first sub-power module, and the power generation control module includes at least one second sub-power module, and at least two of the second sub-power modules share the same pair of positive terminals and negative terminals.

[0008] In a feasible solution, at least one of the first sub-power modules has an independent liner.

[0009] In one feasible solution, the at least two second sub-power modules share a liner.

[0010] In one feasible solution, the driving control module includes three of the first sub-power modules, and the power generation control module includes three of the second sub-power modules.

[0011] In one feasible solution, the at least one first sub-power module is arranged along the first direction, and / or the at least one second sub-power module is arranged along the first direction.

[0012] In one feasible solution, the three second sub-power modules share a liner.

[0013] In one feasible solution, at least one positive terminal or at least one negative terminal of the power module is configured to be connected to the same transfer terminal.

[0014] In one feasible solution, each of the sub-power modules includes a first terminal and a second terminal, and projections of the first terminal and the second terminal on the plane where the liner is located at least partially overlap.

[0015] An embodiment of the present application further provides a motor controller, comprising any of the power modules described above.

[0016] An embodiment of the present application also provides an electric drive assembly, comprising any of the motor controllers described above.

[0017] An embodiment of the present application also provides a vehicle, comprising the electric drive assembly described above.

[0018] The application embodiment further provides another power module, comprising a drive control module and a power generation control module arranged along a first direction;

[0019] The drive control module includes a plurality of first sub-power modules with independent liner plates, and the plurality of first sub-power modules are arranged along the first direction;

[0020] The power generation control module includes a plurality of second sub-power modules, the plurality of second sub-power modules share a same liner, and the power generation control module shares a pair of positive and negative terminals.

[0021] In a feasible solution, the plurality of first sub-power modules of the drive control module each have independent positive and negative terminals, and all positive terminals or all negative terminals of the power modules are configured to be connected to the same transfer terminal.

[0022] In one feasible solution, the power module includes a first terminal and a second terminal, one of the first terminal and the second terminal is a positive terminal, and the other is a negative terminal;

[0023] The first terminal and the second terminal extend from the same end of the power module along the second direction, the first terminal includes a first terminal segment extending along the second direction, the second terminal includes a second terminal segment extending along the second direction, the first terminal segment and the second terminal segment are arranged in a third direction and at least partially overlap in the first direction;

[0024] The second direction is perpendicular to the first direction, and the third direction is perpendicular to the first direction and perpendicular to the second direction.

[0025] In one feasible solution, the second terminal further includes a third-segment terminal connected to the second-segment terminal, and the third-segment terminal extends along the third direction.

[0026] In one feasible solution, edges of the first terminal and the second terminal on both sides in the first direction are flush.

[0027] In a feasible solution, an insulating member is provided between the first terminal and the second terminal.

[0028] In an implementable solution, the first section terminal and the second section terminal each include a first portion and a second portion, and the first portion is closer to the power module than the second portion;

[0029] The size of the first portion in the first direction is smaller than the size of the second portion in the first direction, or the size of the first portion in the first direction is equal to the size of the second portion in the first direction.

[0030] In a feasible solution, the power module includes two frame parts and two heat sink parts, the drive control module and the power generation control module are respectively installed on the two frame parts, the frame parts and the heat sink parts are stacked in a third direction, and the two heat sink parts correspond to the positions of the drive control module and the power generation control module respectively; one of the frame part and the heat sink part is provided with a plug-in component, and the other is provided with a connecting hole that cooperates with the plug-in component, and the extension direction of the plug-in component is the third direction; the third direction is perpendicular to the first direction.

[0031] In one feasible solution, the plug connector is a buckle, and the buckle is engaged with the connecting hole;

[0032] Alternatively, the connector is a connecting column, and the connecting column is connected to the connecting hole by heat riveting;

[0033] Alternatively, the connector is a threaded stud, which is passed through the connecting hole and fixed by a nut.

[0034] In one feasible solution, the power module includes a frame structure, which is an integrally formed structure and includes two frame parts; and / or, the power module includes a heat sink structure, which is an integrally formed structure and includes two heat sink parts.

[0035] In one feasible solution, the power module includes an AC terminal, which extends out of one end of the frame portion along a second direction. The AC terminal includes a terminal segment connected to the frame portion, and a magnetic core is partially sleeved on the outer periphery of the terminal segment; the second direction is perpendicular to the first direction and perpendicular to the third direction.

[0036] An embodiment of the present application further provides a motor controller, comprising any of the power modules described above.

[0037] In one feasible solution, the motor controller includes a capacitor module, and the capacitor module and the power module are stacked in a third direction;

[0038] The power module is provided with a first terminal and a second terminal at one end portion in the second direction, the first terminal including a first segment terminal extending along the second direction, the second terminal including a second segment terminal extending along the second direction, the first segment terminal and the second segment terminal being arranged in the third direction and at least partially overlapping in the first direction;

[0039] The capacitor module is provided with a third terminal and a fourth terminal;

[0040] The first terminal is electrically connected to the third terminal, and the second terminal is electrically connected to the fourth terminal;

[0041] The second direction is perpendicular to the first direction, and the third direction is perpendicular to the first direction and perpendicular to the second direction.

[0042] In a feasible solution, the third terminal and the fourth terminal are arranged on the surface of the capacitor module facing the power module, and the third terminal and the fourth terminal are arranged opposite to each other in the second direction; the third terminal, the fourth terminal and the first terminal, the second terminal are located at the same end in the second direction.

[0043] In a feasible solution, the second terminal is located between the first terminal and the capacitor module, and the fourth terminal is located between an end of the power module and the third terminal.

[0044] In one feasible solution, the second terminal also includes a third-segment terminal connected to the second-segment terminal, and the third-segment terminal extends along the third direction toward the side where the capacitor module is located; the third-segment terminal and the fourth terminal have a first overlapping area in the third direction, and the two are welded in the first overlapping area.

[0045] In a feasible solution, the first terminal is electrically connected to the third terminal via a transfer terminal.

[0046] In one feasible solution, one end of the transition terminal and the first terminal have a second overlapping area in the second direction, and the two are welded in the second overlapping area;

[0047] The other end of the transfer terminal and the third terminal have a third overlapping area in the third direction, and the two are welded in the third overlapping area.

[0048] In a feasible solution, edges of the third terminal and the fourth terminal on both sides in the first direction are arranged flush.

[0049] In an implementable solution, the third terminal and the fourth terminal each include a third portion and a fourth portion, and the third portion is farther away from the capacitor module than the fourth portion;

[0050] The size of the third portion in the first direction is smaller than the size of the fourth portion in the first direction, or the size of the third portion in the first direction is equal to the size of the fourth portion in the first direction.

[0051] In a feasible solution, the driving control module and the power generation control module share the same capacitor module.

[0052] An embodiment of the present application also provides an electric drive assembly, comprising any of the motor controllers described above.

[0053] An embodiment of the present application also provides a vehicle, comprising the electric drive assembly described above.

[0054] The power module provided in the embodiments of this application can be used as a component of a motor controller and applied to electric drive assemblies, particularly in new energy vehicles. In this embodiment, at least two of the multiple sub-power modules of the power module share the same pair of positive and negative terminals. This reduces the space occupied by the positive and negative terminals of the power module, thereby reducing the volume of the power module and conserving terminal materials, thereby reducing costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] Figure 1This is a structural diagram of a power module in the related art;

[0056] Figure 2 This is a front view schematic diagram of a power module in the related art;

[0057] Figure 3 This is a schematic diagram of the back side of a power module in the related art;

[0058] Figure 4a This is a structural diagram of the power module in the first embodiment provided in this application;

[0059] Figure 4b This is a structural diagram of the power module in the second embodiment provided by this application;

[0060] Figure 4c This is a structural diagram of the power module in the third embodiment provided in this application;

[0061] Figure 4d This is a structural diagram of the power module in the fourth embodiment provided by this application;

[0062] Figure 5 A structural diagram of a power module in one embodiment provided in this application at one viewing angle;

[0063] Figure 6 A structural diagram of a power module in another embodiment provided in this application;

[0064] Figure 7 This is a front view of a power module according to an embodiment of the present application;

[0065] Figure 8 This is a schematic diagram of the back side of a power module according to an embodiment of the present application;

[0066] Figure 9 A partial cross-sectional view of the frame portion and the heat dissipation plate portion at the location of the connector in a specific embodiment;

[0067] Figure 10 This is a structural diagram of a motor controller in one embodiment provided in the present application;

[0068] Figure 11 A partial test diagram of the terminal connection structure of the power module and the capacitor module of the motor controller provided in an embodiment of the present application;

[0069] Figure 12 for Figure 11 A top view of the motor controller shown;

[0070] Figure 13 for Figure 11 Right side view of the motor controller shown without the adapter terminals connected;

[0071] Figure 14 for Figure 11 Right side view of the motor controller shown.

[0072] Figures 1 to 3 Description of reference numerals in FIG:

[0073] Power module 100', drive control module 110', first sub-power module 111', power generation control module 120', second sub-power module 121', frame 130', heat sink 140', positive terminal 150', negative terminal 160', phase copper busbar 170', screw 180';

[0074] Figures 4a to 14 Description of reference numerals in FIG:

[0075] Power module 100, sub-power module 101, liner 102, drive control module 110, first sub-power module 111, power generation control module 120, second sub-power module 121, frame structure 130, first frame portion 131, second frame portion 132, connector 133, heat sink structure 140, first heat sink portion 141, second heat sink portion 142, connection hole 143, AC terminal 170, magnetic core 190;

[0076] First terminal T1, first section terminal T11, second terminal T2, second section terminal T21, third section terminal T22;

[0077] Capacitor module 200, third terminal T3, fourth terminal T4, transfer terminal T5. DETAILED DESCRIPTION

[0078] New energy vehicles utilize electricity to propel the vehicle through an electric drive assembly. For example, a core component of a range-extended vehicle is the range extender. Its primary function is to activate the range extender when the power battery's charge drops below a certain level, allowing the engine to drive the generator motor. This generated electricity is partially used to power the drive motor and partially used to recharge the power battery. Once the power battery is fully charged, the range extender deactivates, and the power battery continues to drive the drive motor.

[0079] Extended-range vehicles offer many advantages, including:

[0080] For daily commuting in cities, extended-range electric vehicles can run purely on electricity, producing zero emissions and reducing exhaust pollution, thus meeting environmental requirements. Furthermore, electric drive is more energy-efficient than fuel-powered vehicles, reducing energy consumption and operating costs.

[0081] Extended-range electric vehicles are equipped with an engine as a range extender. When the battery power is low, the engine can start to generate electricity to provide continuous power for the vehicle, avoiding the additional problem of range anxiety caused by the limited cruising range of pure electric vehicles, making long-distance travel more convenient.

[0082] In addition, extended-range vehicles also have the following advantages in driving experience:

[0083] Pure Electric Drive: The extended-range topology is essentially a pure electric drive system. The vehicle's driving power is entirely provided by the drive motor. The engine does not directly drive the vehicle, but rather acts as a generator. When the battery is low, it starts up and converts fuel into electricity to power the drive motor or charge the battery. This pure electric drive method ensures a single, pure power source, consistent with the drive method of pure electric vehicles, fundamentally ensuring a comfortable driving experience.

[0084] Rapid Power Response: The drive motor's characteristics dictate its ability to deliver maximum torque instantaneously. In a range-extended vehicle, when the driver depresses the accelerator, the drive motor responds instantly, delivering a burst of powerful power for rapid starts and acceleration. This immediate power response far surpasses that of traditional fuel vehicles, providing the driver with a more direct and powerful sense of push, ensuring a smooth driving experience, whether in frequent starts and stops in urban areas or overtaking on highways.

[0085] No power interruptions: Since the extended-range vehicle is constantly driven by the electric motor, there's no power interruption during gear shifts, as with traditional fuel-powered vehicles. Power delivery remains continuous and smooth, whether at low or high speeds. Even when the battery is low and the engine starts generating power, the system's sophisticated control strategy ensures unimpeded power delivery from the electric motor, preventing jerks or power interruptions. This provides the driver with a consistent, stable driving experience, enhancing both comfort and safety.

[0086] The electric drive assembly of an extended-range vehicle (ERV) includes components such as a generator motor, a drive motor, a drive control module, and a generator control module. In conventional ERVs, the drive control module and generator control module are two separate components, each with its own power module (e.g., using diode semiconductors, IGBT semiconductors, or SiC semiconductors for AC-DC conversion), current sensors, temperature sensors, and motor rotor position sensors. These components are relatively heavy, bulky, and costly, requiring urgent optimization.

[0087] For ease of understanding and description, the terms used in the following text are explained as follows.

[0088] Taking a three-phase full bridge as an example, the drive control module and the power generation control module each include three bridge arms, and each bridge arm includes an upper bridge arm and a lower bridge arm.

[0089] The upper bridge arm and the lower bridge arm each include a first chip and a second chip connected in reverse parallel therewith. The first chip may be an IGBT (Insulated Gate Bipolar Transistor), and the second chip may be a fast recovery diode. The first chip may be made of SiC.

[0090] A sub-power module refers to a bridge arm, including an upper bridge arm and a lower bridge arm. Each sub-power module corresponds to one phase. These sub-power modules include the first sub-power module of the drive control module and the second sub-power module of the power generation control module.

[0091] As used herein, “above” includes two or more. As used herein, “above” includes the number itself, for example, “above two” includes two, and “above three” includes three.

[0092] Please refer to Figures 1 to 3 , Figure 1 This is a structural diagram of a power module in the related art. Figure 2 This is a front view of a power module in the related art. Figure 3 This is a schematic diagram of the back side of a power module in the related art.

[0093] In a typical solution, the electric drive assembly features a dual electronic control structure. Its power module 100' includes a drive control module 110' and a power generation control module 120'. Drive control module 110' is the core component that converts DC power to AC power and is used to connect to the drive motor. Power generation control module 120' is the core component that converts AC power to DC power and is used to connect to the generator motor. Both the drive motor and the generator motor can be three-phase motors.

[0094] like Figure 1 As shown, the drive control module 110' and power generation control module 120' of the power module 100' are two relatively independent structures, arranged along a first direction x and integrated together. Specifically, the drive control module 110' is mounted on one frame 130', and the power generation control module 120' is mounted on another frame 130'. Each frame 130' is connected to a heat sink 140' in a third direction z to dissipate heat from the corresponding control module.

[0095] For example, in the case where both the drive motor and the generator motor are three-phase motors, the drive control module 110' includes three first sub-power modules 111', which can be connected in a one-to-one correspondence with the three-phase AC terminals of the three-phase drive motor. The power generation control module 120' includes three second sub-power modules 121', which can be connected in a one-to-one correspondence with the three-phase AC terminals of the three-phase generator motor.

[0096] Each first sub-power module 111' of the drive control module 110' utilizes a separate backing plate. Each first sub-power module 111' has a positive terminal 150' and a negative terminal 160' extending outside the frame 130' at one end in the second direction, and a phase copper busbar 170' extending outside the frame 130' at the other end in the second direction. Each second sub-power module 121' of the power generation control module 120' utilizes a separate backing plate. Each second sub-power module 121' has a positive terminal 150' and a negative terminal 160' extending outside the frame 130' at one end in the second direction, and a phase copper busbar 170' extending outside the frame 130' at the other end in the second direction.

[0097] The package dimensions A and B of the power module 100 ′ described above are relatively large when in use, which is very unfriendly to the volume and weight of the entire electronic control unit and limits the layout of the entire vehicle.

[0098] Specifically, if Figure 2 and Figure 3 As shown, the maximum envelope length of the power module 100' is limited by the lengths A11, A12, A13, and A14 of the reinforcement ribs of the frame 130' corresponding to the drive control module 110', the sizes A1a, A1b, and A1c of the lining plates of the drive control module 110', the lengths A21, A22, A23, and A24 of the reinforcement ribs of the frame 130' corresponding to the power generation control module 120', the sizes A2a, A2b, and A2c of the lining plates of the power generation control module 120', and the assembly gap d between the two frames 130'. Therefore, the length dimension A of the power module 100' in the first direction x is too large.

[0099] Specifically, if Figure 2 and Figure 3As shown, the maximum width of the envelope of the power module 100' is limited by the maximum occupied width B1 of the positive and negative terminals 150', 160'; the maximum occupied widths B2 and B4 of the assembled frame 130' and heat sink 140'; the dimension B3 of each liner; and the maximum occupied width B5 of the phase copper busbar 170'. Consequently, the width B of the power module 100' in the second direction y is relatively large. Specifically, the screws used to secure the positive and negative terminals 150', 160', and phase copper busbar 170' result in relatively large dimensions B1 and B5. This, combined with the screws 180' securing the frame 130' and heat sink 140', occupy spaces H2 and H4, limiting the reduction of the width B.

[0100] In addition, if Figures 1 to 3 The power module 100' shown does not include a current detection function (i.e., it does not include related functional components). In application, at least one set of current detection components is still required, and the magnetic core size of the current detection component is relatively large, with a width denoted as Bc. Thus, the combination of the power module 100' and the current detection magnetic core occupies a width of at least B+Bc, resulting in a larger size of the electronic control unit in the width direction.

[0101] Based on the defects of the above-mentioned existing power module 100', the embodiment of the present application provides a power module, which can be referred to Figure 4a , Figure 4a This is a structural diagram of a power module in the first embodiment provided by this application. This power module 100 can be applied to a motor controller. This power module 100 includes multiple sub-power modules 101, each sub-power module 101 corresponding to a phase, and at least two sub-power modules 101 share the same pair of positive and negative terminals. The multiple sub-power modules 101 herein include more than two sub-power modules 101, and more than two includes two.

[0102] Figure 4a Taking a power module 100 as an example, comprising two sub-power modules 101, each sub-power module 101 corresponds to a phase, i.e., the two sub-power modules 101 correspond to two different phases. The power module 100 includes a first terminal T1 and a second terminal T2. One of the first terminal T1 and the second terminal T2 is a positive terminal, and the other is a negative terminal. The two sub-power modules 101 of the power module 100 share a pair of positive and negative terminals, i.e., the two sub-power modules 101 share the first terminal T1 and the second terminal T2.

[0103] Compared with the traditional method in which each sub-power module has an independent positive terminal and negative terminal, the power module 100 provided in this embodiment enables at least two sub-power modules 101 to share the same pair of positive terminals and negative terminals, which can reduce the space occupied by the positive terminals and negative terminals of the power module 100, thereby reducing the occupied volume of the power module 100, and at the same time saving terminal materials, which is conducive to reducing costs.

[0104] In the power module 100 , the sub-power module 101 further includes an AC terminal 170 .

[0105] In other embodiments, the power module 100 may include three or more sub-power modules 101 , wherein at least two sub-power modules 101 share the same pair of positive and negative terminals.

[0106] Taking the example of a power module 100 including three sub-power modules 101, the three sub-power modules 101 can correspond to the U phase, the V phase, and the W phase, respectively. For the convenience of explanation, the three sub-power modules 101 are referred to as sub-power module A, sub-power module B, and sub-power module C, respectively. In some examples, sub-power module A and sub-power module B can share the same pair of positive and negative terminals, and sub-power module C has independent positive and negative terminals; in other examples, sub-power module A and sub-power module C can share the same pair of positive and negative terminals, and sub-power module B has independent positive and negative terminals; in other examples, sub-power module A has independent positive and negative terminals, and sub-power module B and sub-power module C share the same pair of positive and negative terminals; in other examples, sub-power module A, sub-power module B, and sub-power module C can share the same pair of positive and negative terminals.

[0107] Taking the example of a power module 100 including four sub-power modules 101, the four sub-power modules 101 are respectively referred to as sub-power module A, sub-power module B, sub-power module C, and sub-power module D. In some examples, sub-power module A and sub-power module B can share the same pair of positive and negative terminals, and sub-power module C and sub-power module D can share the same pair of positive and negative terminals; in other examples, sub-power module A, sub-power module B, and sub-power module C can share the same pair of positive and negative terminals, and sub-power module D has independent positive and negative terminals; in still other examples, sub-power module A, sub-power module B, sub-power module C, and sub-power module D can all share the same pair of positive and negative terminals.

[0108] In some embodiments, in the power module 100, at least two sub-power modules 101 that share a positive terminal and a negative terminal also share a backing plate. In other words, in the power module 100, at least two sub-power modules 101 share both the same pair of positive and negative terminals and the backing plate 102. Specifically, the phrase "at least two sub-power modules 101 sharing a backing plate 102" herein can be understood as at least two sub-power modules 101 sharing the same backing plate 102, or it can be understood as at least two sub-power modules 101 sharing different backing plates. For example, when the number of sub-power modules 101 is less than three, only the same backing plate 102 can be shared. When the number of sub-power modules 101 exceeds four, this embodiment can include a method in which all four sub-power modules 101 share the same backing plate 102, or a method in which each of the four sub-power modules 101 shares a different backing plate 102. Similarly, as the number of sub-power modules 101 increases, there will be more instances of sharing a backing plate. The term "shared backing plate" described in this embodiment includes all combinations of shared backing plates. All other descriptions of “common lining plate” below include the meaning explained here.

[0109] refer to Figure 4b , Figure 4b This is a structural diagram of the power module of the second embodiment provided in this application. Figure 4b As shown, the power module 100 is still described as including two sub-power modules 101. The two sub-power modules 101 of the power module 100 not only share the same pair of positive and negative terminals, but also share a liner 102. This reduces the overall outer dimensions of the power module 100, further reducing the volume occupied by the power module 100. This also helps conserve material for the liner 102, thereby reducing costs.

[0110] Take the two sub-power modules 101 of the power module 100 arranged along the first direction x as an example, Figure 4a and Figure 4b After the two sub-power modules 101 sharing the same pair of positive and negative terminals share the same liner 102 , the overall size of the power module 100 in the first direction x is significantly reduced.

[0111] In an embodiment in which the power module 100 includes three sub-power modules 101, in some examples, the A sub-power module and the B sub-power module share the same pair of positive and negative terminals, the C sub-power module has an independent positive and negative terminal, the A sub-power module and the B sub-power module can further share a liner, and the C sub-power module has an independent liner; in other examples, the A sub-power module, the B sub-power module, and the C sub-power module share the same pair of positive and negative terminals, and the A sub-power module, the B sub-power module, and the C sub-power module further share a liner, as described later. Figure 5The power generation control module 120 is shown.

[0112] In an embodiment where the power module 100 includes more than four sub-power modules 101 , similar configurations may be employed and will not be described in detail.

[0113] In some embodiments, the power module 100 includes multiple sub-power modules 101, each sub-power module 101 corresponds to a phase, at least two sub-power modules 101 share the same pair of positive terminals and negative terminals, and among the multiple sub-power modules 101 of the power module 100, at least two sub-power modules 101 share a liner 102.

[0114] Here, at least two sub-power modules 101 sharing the backing plate 102 may share the same pair of positive and negative terminals, or may not share the positive and negative terminals, that is, there is no necessary connection between the sub-power modules 101 sharing the backing plate 102 and the sub-power modules 101 sharing the same pair of positive and negative terminals.

[0115] The following is a detailed description using an example where the power module 100 includes three sub-power modules 101 .

[0116] Some examples, such as Figure 4c As shown, power module 100 includes three sub-power modules 101, two of which share the same pair of positive and negative terminals, and two of which share a backing plate 102. From left to right in the figure, the first sub-power module 101 has an independent backing plate 102, while the second sub-power module 102 and the third sub-power module 102 share the backing plate 102. The first sub-power module 101 and the second sub-power module 102 share the same pair of positive and negative terminals, namely, the first terminal T1 and the second terminal T2, while the third sub-power module 102 has an independent first terminal T1 and a second terminal T2.

[0117] In other examples, such as Figure 4d As shown, power module 100 includes three sub-power modules 101, two of which share the same pair of positive and negative terminals. Two of these sub-power modules 101 also share a backing plate 102. The two sub-power modules 101 sharing the backing plate 102 are identical to the two sub-power modules 101 sharing the same pair of positive and negative terminals. The two sub-power modules 101 sharing the backing plate 102 also share the same pair of positive and negative terminals. From left to right in the figure, the first sub-power module 101 has an independent backing plate 102 and independent positive and negative terminals. The second and third sub-power modules 101 share both the backing plate 102 and the same pair of positive and negative terminals.

[0118] The above-mentioned at least two sub-power modules 101 sharing the liner 102 includes the situation where at least two sub-power modules 101 of the power module 100 share the same liner 102, and also includes the situation where at least two sub-power modules 101 in the power module 100 share one liner 102, and the other at least two sub-power modules 101 share another liner 102.

[0119] For example, in a solution where the power module 100 includes four sub-power modules 101, the “shared liner” may include the following situations:

[0120] The A sub-power module and the B sub-power module share one liner 102 , and the C sub-power module and the D sub-power module share another liner 102 ;

[0121] Alternatively, the A sub-power module, the B sub-power module, and the C sub-power module share a liner 102, and the D sub-power module has an independent liner 102;

[0122] Alternatively, the A sub-power module, the B sub-power module, the C sub-power module, and the D sub-power module share the same liner 102 .

[0123] In some embodiments, at least one positive terminal or at least one negative terminal of the power module 100 is configured to be connected to the same transfer terminal, thereby facilitating electrical connection between the power module 100 and other components of the motor controller (e.g., the capacitor module 200 described below).

[0124] In some embodiments, the power module 100 includes a first terminal T1 and a second terminal T2, the projections of which on the plane of the substrate 102 at least partially overlap. One of the first terminal T1 and the second terminal T2 is a positive terminal, and the other is a negative terminal.

[0125] With this arrangement, based on formulas (1) to (3) discussed below, the projections of the positive terminal and the negative terminal on the plane where the liner 102 is located at least partially overlap, which can reduce the series inductance in the current loop.

[0126] For at least two sub-power modules 101 that share a positive terminal and a negative terminal, the shared positive terminal and negative terminal belong to each shared sub-power module 101. Figure 4a As shown in the example, in the power module 100 , the first terminal T1 and the second terminal T2 belong to the sub-power module 101 located on the left side of the figure, and also belong to the sub-power module 101 located on the right side of the figure.

[0127] exist Figures 4a to 4dIn the example shown, the plane where the liner 102 is located is the paper surface, and the first terminal T1 and the second terminal T2 can be arranged in a direction perpendicular to the paper surface. In the projection plane of the plane where the liner 102 is located, the first terminal T1 and the second terminal T2 have an overlapping area. Figures 4a to 4d In FIG, the overlapping area is indicated by a gray filled block, the first terminal T1 is located below the second terminal T2, and the dotted line at the boundary of the gray filled block indicates the invisible edge of the first terminal T1.

[0128] exist Figures 4a to 4d In the example shown, the first terminal T1 and the second terminal T2 partially overlap in the projection of the substrate 102. In other embodiments, the first terminal T1 and the second terminal T2 may completely or nearly completely overlap in the projection of the substrate 102.

[0129] In order to enable those skilled in the art to better understand the present application, the present application is further described in detail below in conjunction with specific application examples.

[0130] Please refer to Figure 5 and Figure 6 , Figure 5 This is a structural diagram of a power module in one embodiment of the present application at one viewing angle. Figure 6 This is a structural diagram of a power module in another embodiment provided in the present application.

[0131] In this embodiment, the power module 100 includes a driving control module 110 and a power generation control module 120 .

[0132] The driving control module 110 includes at least one first sub-power module 111 , and the power generation control module 120 includes at least one second sub-power module 121 . At least two second sub-power modules 121 share the same pair of positive and negative terminals.

[0133] After the above configuration, in the power module 100, at least two second sub-power modules 121 of the power generation control module 120 share the same pair of positive terminals and negative terminals, which can reduce the space occupied by the positive terminals and negative terminals of the power module 100, thereby reducing the occupied volume of the power module 100, and at the same time saving terminal materials, which is conducive to reducing costs.

[0134] In some embodiments, at least one first sub-power module 111 is arranged along the first direction x.

[0135] In some embodiments, at least one second sub-power module 121 is arranged along the first direction x.

[0136] In some embodiments, the drive control module 110 and the power generation control module 120 are arranged along a first direction x, that is, at least one first sub-power module 111 and at least one second sub-power module 121 are arranged along the first direction x. The first direction x can be understood as the length direction of the power module 100.

[0137] In some embodiments, the driving control module 110 includes a plurality of first sub-power modules 111 , and the plurality of first sub-power modules 111 are arranged along a first direction x. Figure 5 and Figure 6 Taking the drive motor connected to the drive control module 110 as a three-phase motor as an example, the drive control module 110 includes three first sub-power modules 111, and the three first sub-power modules 111 are arranged along the first direction x. The AC terminals 170 of the three first sub-power modules 111 are used to be connected one-to-one with the three-phase AC terminals of the drive motor.

[0138] In some embodiments, at least one first sub-power module 111 of the drive control module 110 has an independent liner. Figure 5 and Figure 6 In the example shown, the three first sub-power modules 111 of the drive control module 110 each have an independent liner. The three first sub-power modules 111 are arranged along the first direction x, which can also be understood as the three liner being arranged along the first direction x.

[0139] In some embodiments, the power generation control module 120 includes a plurality of second sub-power modules 121 , and at least two of the plurality of second sub-power modules 121 share a common liner. Figure 5 and Figure 6 Taking the generator motor connected to the power generation control module 120 as a three-phase motor as an example, the power generation control module 120 includes three second sub-power modules 121, the three second sub-power modules 121 share a lining plate, and the AC terminals 170 of the three second sub-power modules 121 are used to be connected one-to-one with the three-phase AC terminals of the generator motor.

[0140] In other embodiments, only two of the three second sub-power modules 121 of the power generation control module 120 may share a liner.

[0141] In other embodiments, the power generation control module 120 may include two second sub-power modules 121 , and the two second sub-power modules 121 share a common liner.

[0142] In other embodiments, the power generation control module 120 may include four second sub-power modules 121, and the scheme in which at least two of the four second sub-power modules 121 share a lining plate includes: two of the second sub-power modules 121 share one lining plate, and the remaining two second sub-power modules 121 share another lining plate; or, three of the second sub-power modules 121 share one lining plate, and the remaining second sub-power module 121 has an independent lining plate; or, four second sub-power modules 121 share the same lining plate.

[0143] After the above configuration, since at least two second sub-power modules 121 in the power generation control module 120 share the same lining plate, the number of lining plates of the power module 100 is reduced. Figures 1 to 3 Compared with the solution in which the power generation control module 120' shown uses three independent linings, this embodiment can achieve miniaturization of the lining of the power generation control module 120, effectively reducing the occupied size of the power generation side functional area in the first direction x, and can greatly reduce the occupied size of the power module 100 in the first direction x, thereby making it possible to utilize the reduction in the occupied volume and weight of the entire electronic control machine, and thus making the layout of the entire vehicle more flexible.

[0144] contrast Figure 2 and Figure 7 ,exist Figure 2 In the existing solution shown, the three second sub-power modules 121' of the power generation control module 120' respectively have independent lining plates, and the size of each lining plate in the first direction x is A2a+A2b+A2c. Figure 7 In the embodiment shown, the three second sub-power modules 121 of the power generation control module 120 share the same liner, and the dimension occupied by the liner in the first direction x is A2A. Compared with the existing solution, the length dimension occupied by the power module 100 in the first direction x can be effectively reduced.

[0145] above Figure 5 and Figure 6 In the illustrated embodiment, the power generation control modules 120 share a common backing plate. In other embodiments, if this meets usage requirements, each second sub-power module 121 of the power generation control module 120 may have an independent backing plate, allowing the at least two first sub-power modules 111 of the drive control module 110 to share a backing plate, which can also reduce the footprint of the power module 100 in the first direction x. In other embodiments, if this meets usage requirements, the at least two first sub-power modules 111 of the drive control module 110 may share a backing plate, and the at least two second sub-power modules 121 of the power generation control module 120 may also share a backing plate.

[0146] Below is Figure 5 and Figure 6The power module 100 shown in FIG. 1 is a description object, and various improvements to the power module 100 of the present application are specifically described.

[0147] In some embodiments, at least two second sub-power modules 121 of the power generation control module 120 may share a pair of positive and negative terminals. Figure 5 and Figure 6 In the illustrated example, the three second sub-power modules 121 of the power generation control module 120 share the same pair of positive and negative terminals. In practice, the three second sub-power modules 121, originally three independent single-phase half-bridge circuits, can be integrated into a DBC (Direct Bonded Copper) full-bridge circuit. This allows the three second sub-power modules 121 of the power generation control module 120 to share the same pair of positive and negative terminals, reducing the number of DC terminals and making the power generation control module 120 occupy a smaller volume.

[0148] In some embodiments, at least two sub-power modules 101 in the power module 100 may be provided with the same pair of first terminals T1 and second terminals T2, and the other sub-power modules 101 may be provided with first terminals T1 and second terminals T2, respectively. In other embodiments, all second sub-power modules 121 in the power generation control module 120 may share the same pair of positive and negative terminals, that is, only one first terminal T1 and one second terminal T2 are provided on the power generation control module 120, and all first sub-power modules 111 in the drive control module 110 are provided with independent first terminals T1 and second terminals T2, respectively.

[0149] like Figure 5 and Figure 6 As shown, the first terminal T1 and the second terminal T2 are located at the same end of the power module 100 in the second direction y. The second direction y is perpendicular to the first direction x and can be understood as the width direction of the power module 100.

[0150] The AC terminals 170 of each sub-power module of the power module 100 are located at the same end of the power module 100 in the second direction y. The AC terminal 170 and the first terminal T1 and the second terminal T2 are respectively disposed at two ends of the power module 100 in the second direction y.

[0151] Figure 5 and Figure 6In the illustrated example, the backing plate of each first sub-power module 111 of the drive control module 110 extends to a pair of first terminals T1 and second terminals T2. That is, each of the multiple first sub-power modules 111 of the drive control module 110 has its own independent positive and negative terminals. The backing plate of the power generation control module 120 extends to a pair of first terminals T1 and second terminals T2. The three second sub-power modules 121 of the power generation control module 120 share the same first terminal T1 and the same second terminal T2.

[0152] In some embodiments, at least one positive terminal or at least one negative terminal of the power module 100 is configured to be connected to the same transfer terminal T5 (indicated at Figure 10 In this way, the integration of the power module 100 is improved, and the electrical connection between the power module 100 and other components of the motor controller (such as the capacitor module) is facilitated.

[0153] In application, all positive terminals or all negative terminals of the power module 100 may be configured to be connected to the same switching rotor T5 .

[0154] by Figure 5 and Figure 6 In the example shown, all positive terminals of the power module 100 include the positive terminals of all first sub-power modules 111 and the positive terminal of the power generation control module 120; all negative terminals of the power module 100 include the negative terminals of all first sub-power modules 111 and the negative terminal of the power generation control module 120.

[0155] In some embodiments, the power module 100 includes two frames and two heat sinks. The drive control module 110 and the power generation control module 120 are mounted on the two frames, respectively. The frames and the heat sinks are stacked in a third direction z, with the two heat sinks corresponding to the positions of the drive control module 110 and the power generation control module 120, respectively. In this way, the two heat sinks can dissipate heat from the drive control module 110 and the power generation control module 120, respectively, to ensure normal operation of the drive control module 110 and the power generation control module 120.

[0156] exist Figure 5 and Figure 6In the illustrated embodiment, the two frame portions are a first frame portion 131 and a second frame portion 132. The drive control module 110 is mounted on the first frame portion 131, and the power generation control module 120 is mounted on the second frame portion 132. The two heat sink portions are a first heat sink portion 141 and a second heat sink portion 142. The first frame portion 131 and the first heat sink portion 141 are stacked in a third direction z. The first heat sink portion 141 is used to dissipate heat from the drive control module 110 mounted on the first frame portion 131. The second frame portion 132 and the second heat sink portion 142 are stacked in the third direction z. The second heat sink portion 142 is used to dissipate heat from the power generation control module 120 mounted on the second frame portion 132.

[0157] The third direction z is perpendicular to the first direction x and the second direction y. The third direction z can be understood as the height direction of the power module 100 .

[0158] Please refer to Figure 7 and Figure 8 , Figure 7 and Figure 8 The front and back schematic diagrams of the power module are shown respectively. The front side refers to the side where the drive control module 110 and the power generation control module 120 are located, and the back side refers to the side where the heat dissipation plate is located.

[0159] In this embodiment, connectors 133 are provided at both ends of the face of the frame portion facing the heat sink portion in the second direction y, and the heat sink portion has connection holes 143 that mate with the connectors 133. Specifically, the first frame portion 131 has connectors 133 at both ends in the second direction y, and the first heat sink portion 141 has connection holes 143 at both ends in the second direction y. The first frame portion 131 and the first heat sink portion 141 are connected via the mating connectors 133 and connection holes 143. The second frame portion 132 has connectors 133 at both ends in the second direction y, and the second heat sink portion 142 has connection holes 143 at both ends in the second direction y. The second frame portion 132 and the second heat sink portion 142 are connected via the mating connectors 133 and connection holes 143. It will be understood that the extension direction of the connectors 133 is the third direction z.

[0160] The frame portion and the heat dissipation plate portion are connected in the above manner, which is beneficial to reducing the size of the power module 100 in the second direction y. Figure 2 、 Figure 3 and Figure 7 、 Figure 8Since the connector 133 is disposed on a side surface of the frame portion facing the heat sink portion, it does not interfere with the first terminal T1 and the second terminal T2. Therefore, the first terminal T1 and the second terminal T2 can be retracted, at least partially occupying the space B2 originally occupied by the screw 180', thereby reducing the original size B1. In this solution, the size B11 occupied by the first terminal T1 and the second terminal T2 in the second direction y is smaller, which can further reduce the overall envelope size and occupied volume of the power module 100.

[0161] Based on the connection between the frame and the heat sink using connectors 133 and connection holes 143, the power module 100 can include a magnetic core 190. The magnetic core 190 can be partially mounted around the periphery of the AC terminal 170, located in the space B4 originally occupied by the screw 180' connection. Specifically, the AC terminal 170 includes an end extending from the frame along the second direction y. The AC terminal 170 includes a terminal segment connected to the frame, and the magnetic core 190 is mounted around the periphery of the terminal segment. Thus, compared to existing solutions, the width of the power module 100 equipped with the magnetic core 190 in the second direction y is reduced by at least Bc (the width originally occupied by the magnetic core), further reducing the overall envelope size and occupied volume of the power module 100.

[0162] In the illustrated embodiment, connector 133 is disposed on the frame, and connection hole 143 is disposed on the heat sink. In other embodiments, if the placement of magnetic core 190 on the frame is not affected, connector 133 may be disposed on the heat sink, and connection hole 143 may be disposed on the frame. Alternatively, some connector 133 may be disposed on the heat sink, and some on the frame.

[0163] In this embodiment, since the multiple second sub-power modules 121 of the power generation control module 120 are integrated on the same liner, the number of reinforcing ribs of the second frame portion 132 corresponding to the power generation control module 120 can be reduced compared with the existing solution. Figure 2 As shown in the existing solution, the frame 130' corresponding to the power generation control module 120' is provided with a reinforcing rib between two adjacent lining plates; Figure 7 As shown, in this embodiment, since the power generation control module 120 is provided with only one liner, the second frame portion 132 can omit the reinforcing ribs originally provided between two adjacent liner plates, thereby further reducing the length of the power module 100 in the first direction x.

[0164] In one implementation example, the power module 100 includes a frame structure 130. The frame structure 130 is an integrally formed structure. The frame structure 130 includes two frame parts, namely, the frame structure 130 includes a first frame part 131 and a second frame part 132. In other words, the first frame part 131 and the second frame part 132 are integrated into one frame structure 130. In this way, the assembly gap d between the two frames 130' in the existing solution can be eliminated, and the number of reinforcing ribs can also be reduced. That is, the two reinforcing ribs at the assembly joint of the two frames 130' can be reduced to one reinforcing rib. Figure 2 、 Figure 3 and Figure 7 、 Figure 8 It is understood that the length of the power module 100 in the first direction x can be further reduced.

[0165] like Figure 2 As shown, in the existing solution, the power module 100' has 8 reinforcing ribs and an assembly gap d, wherein the corresponding dimensions of the 8 reinforcing ribs are A11, A12, A13, A14, A21, A22, A23, and A24 respectively. Figure 7 As shown, in an implementation example, the power module 100 has five reinforcing ribs and no assembly gap d, wherein the corresponding dimensions of the five reinforcing ribs are A11, A12, A13, A21, and A22, respectively.

[0166] In other implementation examples, according to assembly requirements and actual application requirements, the first frame portion 131 and the second frame portion 132 of the power module 100 may also be configured as two relatively independent separate structures.

[0167] In one implementation example, the power module 100 includes a heat sink structure 140. This heat sink structure 140 is an integrated structure and comprises two heat sink portions: a first heat sink portion 141 and a second heat sink portion 142. In other words, the first heat sink portion 141 and the second heat sink portion 142 are integrated into a single heat dissipation structure. This facilitates assembly of the heat sink structure 140 with the frame structure 130, simplifying the assembly process.

[0168] Illustratively, the heat sink structure 140 may be a liquid cooling plate having a flow channel therein for circulating cooling liquid.

[0169] For example, the surface of the heat dissipation plate structure 140 facing away from the frame structure 130 may be provided with heat dissipation fins.

[0170] The connector 133 of the frame portion for connecting with the heat sink portion can have various structural forms.

[0171] In an implementation example, Figure 9As shown in Figure (a), the connector 133 can be a buckle having a plurality of elastic hooks 1331 with engaging surfaces facing the frame. During assembly, the elastic hooks 1331 of the frame can be deformed toward the center of the buckle under elastic action to reduce their size and pass through the connection hole 143 of the heat sink. After passing through the connection hole 143, the elastic hooks 1331 are reset away from the center of the buckle under elastic action, so that the engaging surfaces of the elastic hooks 1331 can engage the end surface of the heat sink facing away from the frame, thereby completing the connection between the frame and the heat sink.

[0172] In other implementation examples, such as Figure 9 As shown in (b), connector 133 can be a connecting post. After passing through connection hole 143 of the heat sink, the connecting post is connected to the heat sink by heat riveting. Specifically, the end of the connecting post passing through connection hole 143 can expand and deform under the action of heat riveting to form a nail cap structure 1332 larger than the aperture of connection hole 143. Nail cap structure 1332 abuts the end surface of the heat sink facing away from the frame, thereby connecting the frame and heat sink.

[0173] In other implementation examples, the connector 133 may also be a threaded stud, which may be fixed by a nut after passing through the connection hole 143 of the heat dissipation plate.

[0174] In this embodiment, the first terminal T1, the second terminal T2 and the AC terminal 170 extending from the lining plate can be connected to the frame portion. The frame portion can be made of plastic or other materials, and the plastic or other materials of the frame portion can achieve insulation isolation of the terminals.

[0175] In the embodiment of the present application, the power module 100 integrates the drive control module 110 and the power generation control module 120, wherein the multiple second sub-power modules 121 in the power generation control module 120 share the same lining plate, and may also share the same positive terminal and the same negative terminal. The multiple first sub-power modules 111 of the drive control module 110 each have an independent lining plate, and also have independent positive terminals and negative terminals. In other embodiments, the structure of the drive control module 110 is not limited to the above, and the three first sub-power modules 111 in the drive control module 110 may also be a full bridge and share the same pair of positive and negative terminals. The drive control module 110 may also adopt other multi-phase full-bridge structures.

[0176] This embodiment also improves the arrangement of the first terminal T1 and the second terminal T2 of the power module 100. Here, the first terminal T1 and the second terminal T2 refer to the positive and negative terminals in the same current loop. This reduces the series inductance in the current loop in which the power module 100 resides. For simplicity, this will be described below in conjunction with the motor controller.

[0177] An embodiment of the present application further provides a motor controller, which includes the power module 100 described in the above embodiment.

[0178] A motor controller can be used to control the operating state of a vehicle's motor. For example, in the case of a three-phase motor, when the motor controller performs high-speed on / off control of the power module 100, a surge voltage V is applied to the current loop containing the power module 100. This surge voltage V is proportional to the series inductance Ls introduced by the terminals in the current loop.

[0179] The calculation formula for surge voltage is:

[0180] in, is the rate of change of current in the current loop.

[0181] Assuming that the width of the positive terminal and the negative terminal of the current loop are both W, the length are both L, and the thickness are both t, the empirical calculation formula for Ls of the positive terminal and the negative terminal in the current loop is:

[0182]

[0183] Where L1 and L2 represent the self-inductance of the positive and negative terminals, respectively; M represents the mutual inductance between the positive and negative terminals; and k represents the coupling coefficient, which characterizes the degree of coupling between the positive and negative terminals. Misalignment between the centers of the positive and negative terminals affects the value of k. If Ws:W ≠ 1, then k < 1. The smaller the Ws:W value, the greater the misalignment between the centers of the positive and negative terminals, and the smaller the k value. Ws represents the overlap width between the positive and negative terminals.

[0184] Based on the above formula (2), the formula of Ls can be expressed as:

[0185]

[0186] Where μ0 is the magnetic permeability in vacuum.

[0187] According to formula (1) and formula (3), the smaller L is, the larger W is, and the larger t is, the smaller Ls is, and the smaller V is; the larger Ws:W is, the greater the overlap ratio of the two terminals is, the larger k is, the smaller Ls is, and the smaller V is.

[0188] Please refer to Figure 10 , Figure 10 This is a structural diagram of a motor controller in one embodiment of the present application. To clearly illustrate the terminal connection structure of the power module 100 and the capacitor module 200, Figure 10 Components such as the frame structure 130 in the power module 100 are omitted.

[0189] like Figure 10 As shown, in some embodiments, the motor controller further includes a capacitor module 200, and the capacitor module 200 and the power module 100 are stacked in the third direction z. In this way, the size of the space occupied by the motor controller can be reduced.

[0190] The capacitor module 200 can be used in conjunction with the power module 100 in the motor controller to balance the DC bus voltage.

[0191] Capacitor module 200 includes a third terminal T3 and a fourth terminal T4. One of the third terminal T3 and the fourth terminal T4 is a positive terminal, and the other is a negative terminal. The third terminal T3 can be electrically connected to the first terminal T1 of the power module 100, and the fourth terminal T4 can be electrically connected to the second terminal T2 of the power module 100.

[0192] Exemplarily, the first terminal T1 and the third terminal T3 may both be positive terminals, and the second terminal T2 and the fourth terminal T4 may both be negative terminals.

[0193] Exemplarily, the first terminal T1 and the third terminal T3 may both be negative terminals, and the second terminal T2 and the fourth terminal T4 may both be positive terminals.

[0194] Please refer to Figure 11 and Figure 12 , Figure 11 This is a partial test diagram of the terminal connection structure of the power module and the capacitor module of the motor controller in an embodiment provided in this application. Figure 12 for Figure 11 A top view of the motor controller is shown.

[0195] In the power module 100 provided in this embodiment, the first terminal T1 and the second terminal T2 extend from the same end of the power module 100 along the second direction y. The first terminal T1 includes a first terminal segment T11 extending along the second direction y, and the second terminal T2 includes a second terminal segment T21 extending along the second direction y. The first terminal segment T11 and the second terminal segment T21 are arranged in the third direction z and at least partially overlap in the first direction x.

[0196] After the above arrangement, the first segment terminal T11 of the first terminal T1 and the second segment terminal T21 of the second terminal T2 are stacked in the third direction z so that the two can at least partially overlap in the first direction x, which is beneficial to increase Ws / W, thereby increasing the k value in the aforementioned formula (2), reducing Ls, and further reducing the surge voltage V, which can improve the performance of the motor controller.

[0197] exist Figures 1 to 3 In the prior art shown, the positive terminal 150' and the negative terminal 160' of the power module 100' are arranged side by side along a first direction x. There is no overlap between the positive and negative terminals in this first direction x. In this region, the Ws value is zero. Based on the aforementioned formula (3), the series inductance between the positive and negative terminals 150', 160' is relatively large. Furthermore, due to the side-by-side arrangement of the positive and negative terminals 150', 160', their dimensions in the first direction x are limited. Specifically, the dimensions of the positive and negative terminals 150', 160' in the first direction x are no greater than half the dimensions of the liner from which they are connected in the first direction x.

[0198] By comparison, in this embodiment, the stacking of the first segment T11 and the second segment T21 of the first terminal T1 in the third direction z not only allows them to overlap in the first direction x, but also ensures that their dimensions in the first direction x are not restricted. Theoretically, in this embodiment, the dimensions of the first segment T11 and the second segment T21 in the first direction x can approximate the dimensions of the substrate from which they are connected in the first direction x. This arrangement of the first and second terminals T1 and T2 in this embodiment effectively reduces the series inductance in the current loop.

[0199] In a specific implementation, the edges of the first terminal T1 and the second terminal T2 on both sides in the first direction x are flush. The flushing here means that the two edges of the first terminal T1 and the second terminal T2 on the same side in the first direction x are completely aligned or nearly aligned. In this way, 100% or approximately 100% overlap of the first terminal T1 and the second terminal T2 in the first direction x can be achieved. Within the range of the second segment terminal T21 extending along the second direction y, the first terminal T1 and the second terminal T2 can have the same or similar graphic structures, which can be referred to. Figure 12 It is understood that this allows the first terminal T1 and the second terminal T2 to have a larger overlapping area, thereby reducing ESL to a greater extent.

[0200] Please refer to Figure 13 and Figure 14 , Figure 13 for Figure 11 The motor controller is shown in the right view without the adapter terminals connected. Figure 14 for Figure 11 Right side view of the motor controller shown.

[0201] In the motor controller provided in this embodiment, a third terminal T3 and a fourth terminal T4 are provided on the surface of the capacitor module 200 facing the power module 100. The third terminal T3 and the fourth terminal T4 are arranged opposite each other in the second direction y. The third terminal T3 and the fourth terminal T4 are located at the same end as the first terminal T1 and the second terminal T2 in the second direction to facilitate electrical connection between the third terminal T3 and the first terminal T1, and to facilitate electrical connection between the fourth terminal T4 and the first terminal T2.

[0202] After the above arrangement, the third terminal T3 and the fourth terminal T4 of the capacitor module 200 are arranged relative to each other in the second direction y, so that the third terminal T3 and the fourth terminal T4 can be stacked in the second direction y, which is equivalent to increasing the overlapping width between the two, that is, it is beneficial to increase Ws / W, increase the k value, reduce Ls, and make the surge voltage V smaller, which can improve the performance of the motor controller.

[0203] In a specific implementation, the edges of the third terminal T3 and the fourth terminal T4 on both sides in the first direction x are arranged flush. The flushing here means that the two edges of the third terminal T3 and the fourth terminal T4 on the same side in the first direction x are completely aligned or nearly aligned. In this way, 100% or approximately 100% overlap of the third terminal T3 and the fourth terminal T4 in the first direction x can be achieved. Within the range of the third terminal T3 extending along the third direction z, the third terminal T3 and the fourth terminal T4 can have the same or similar graphic structures, which can be referred to. Figure 13 and Figure 14 It is understood that this allows the third terminal T3 and the fourth terminal T4 to have a larger overlapping area, thereby reducing ESL to a greater extent.

[0204] In the motor controller, the above-mentioned configuration of the first terminal T1 and the second terminal T2 of the power module 100, combined with the above-mentioned configuration of the third terminal T3 and the fourth terminal T4 of the capacitor module 200, can effectively reduce ESL (Equivalent Series Inductance) and improve the circuit stability of the motor controller.

[0205] In some embodiments, the second terminal T2 is located between the first terminal T1 and the capacitor module 200, and the fourth terminal T4 is located between the end of the power module 100 and the third terminal T3. This arrangement facilitates electrical connection between the first terminal T1 and the third terminal T3, as well as between the second terminal T2 and the fourth terminal T4, without interference between the two terminals. Furthermore, the structure formed by the connection of the first terminal T1 and the third terminal T3 can be stacked with the structure formed by the connection of the second terminal T2 and the fourth terminal T4, which helps increase the overlap width Ws between the two connection structures and thus helps reduce ESL.

[0206] In a specific implementation, the third terminal T3 and the fourth terminal T4 of the capacitor module 200 can be led out from the surface of the capacitor module 200 facing the power module 100, that is, the third terminal T3 and the fourth terminal T4 are perpendicular to the surface of the capacitor module 200 facing the power module 100. In this way, the terminal arrangement of the capacitor module 200 is simple and helps to reduce the loop length of the current loop, thereby facilitating the reduction of ESL.

[0207] The terminals of the power module 100 and the capacitor module 200 may be electrically connected by welding to reduce the connection resistance between the terminals.

[0208] In one implementation, the second terminal T2 of the power module 100 further includes a third-segment terminal T22 connected to the second-segment terminal T21, and the third-segment terminal T22 extends along a third direction z. In the motor controller, the third-segment terminal T22 specifically extends toward the capacitor module 100 to facilitate welding connection with the fourth terminal T4.

[0209] like Figure 10 and Figure 11 As shown, the third segment terminal T22 of the second terminal T2 and the fourth terminal T4 have a first overlapping area S1 in the third direction z, and the two are welded in the first overlapping area S1. The welding method can be laser welding or other welding methods, which are not limited here.

[0210] The first terminal T1 of the power module 100 and the third terminal T3 of the capacitor module 200 can be electrically connected through the transfer terminal T5. Figure 10 and Figure 11 In this way, a space for welding the second terminal T2 and the fourth terminal T4 can be reserved between the first terminal T1 and the third terminal T3, which facilitates the welding operation of the two.

[0211] In actual operation, the second terminal T2 and the fourth terminal T4 are welded first, and then the transfer terminal T5 is welded to the first terminal T1 and the third terminal T3 respectively.

[0212] In one implementation, one end of the adapter terminal T5 and the first terminal T1 have a second overlapping region S2 in the second direction y, and the two are welded in the second overlapping region S2. The other end of the adapter terminal T5 and the third terminal T3 have a third overlapping region S3 in the third direction z, and the third overlapping region S3 of the two are welded.

[0213] In actual operation, the first overlapping area S1 and the third overlapping area S3 are staggered in the third direction z to avoid mutual influence during welding.

[0214] Figure 10 and Figure 11In the example shown, the first terminal T1 only includes the first terminal segment T11. The transition terminal T5 has one end connected to the first terminal T1 extending along the second direction y and the other end extending along the third direction z. The transition terminal T5 is generally L-shaped.

[0215] In other implementations, the first terminal T1 may have other structural forms, and the adapter terminal T5 may be configured accordingly. For example, the first terminal T1 may include a fourth-segment terminal connected to the first-segment terminal T11. The fourth-segment terminal may extend along the third direction z, away from the capacitor module 200. One end of the adapter terminal T5 and the fourth-segment terminal may have an overlapping region in the third direction z, and the two may be welded within the overlapping region. The fourth-segment terminal may also extend toward the capacitor module 200.

[0216] In other embodiments, the first terminal T1 of the power module 100 may also be directly welded to the third terminal T3 of the capacitor module 200 without providing the transfer terminal T5.

[0217] like Figures 11 to 14 As shown, in this embodiment, the terminal connection path of the power module 100 and the capacitor module 200 includes a first area D1, a second area D2, a third area D3 and a fourth area D4.

[0218] An insulating member (not shown) may be provided between the first terminal T1 and the second terminal T2 of the power module 100, so that the positive and negative terminals of the power module 100 can be connected with each other at a smaller terminal spacing h ( Figure 11 Insulation isolation is achieved when the positive terminal and the negative terminal are insulated and isolated, and a smaller terminal spacing h is provided between the positive terminal and the negative terminal in parallel relative portions, which is beneficial to reducing ESL.

[0219] Similarly, an insulating member may be provided between the third terminal T3 and the fourth terminal T4 of the capacitor module 200 so that the positive terminal and the negative terminal of the capacitor module 200 have a smaller terminal spacing while ensuring insulation isolation, thereby facilitating ESL reduction.

[0220] In a specific implementation, the terminal spacing of the power module 100 and the terminal spacing of the capacitor module 200 can be set to be the same or approximately the same.

[0221] In one implementation, the first section terminal T11 of the first terminal T1 and the second section terminal T21 of the second terminal T2 both include a first portion and a second portion, and the first portion is closer to the power module 100 than the second portion. Figure 12 As shown, the dimension W1 of the first portion in the first direction x is smaller than the dimension W2 of the second portion in the first direction x. Figure 5, W1 is set smaller than W2, so as to reserve installation space for the power module 100 to facilitate fixing the frame structure 130.

[0222] In other implementations, if conditions permit, the size W1 of the first portion may be set to be equal to or approximately equal to the size W2 of the second portion.

[0223] In practical applications, the dimensions of the first area D1 and the second area D2 in the second direction y, as well as the values ​​of W1 and W2 can be designed according to product layout requirements and product performance requirements.

[0224] like Figure 13 and Figure 14 As shown, the third terminal T3 and the fourth terminal T4 of the capacitor module 200 each include a third portion and a fourth portion, wherein the third portion is further away from the capacitor module 200 than the fourth portion. The dimension W3 of the third portion in the first direction x is smaller than the dimension W4 of the fourth portion in the first direction x. The third terminal T3 and the fourth terminal T4 partially form the fourth portion in the fourth region D4, and both have a dimension W4 in the first direction x. The third terminal T3 and the fourth terminal T4 partially form the third portion in the third region, and the actual dimension of the third portion of the third terminal T3 in the first direction x is W3-, and the actual dimension of the third portion of the fourth terminal T4 in the first direction x is W3+, where W3+ and W3- are equal to or approximately equal to W3. Setting W3 smaller than W4 allows for reserved installation space to facilitate securing the external housing, making it easier to use the housing to encapsulate and protect the internal components of the motor controller.

[0225] In other implementations, if conditions permit, the size W3 of the third portion may be set to be equal to or approximately equal to the size W4 of the fourth portion.

[0226] In practical applications, W1 < W2 = W3 < W4 can be set. The positive and negative terminals of power module 100 have a relatively small size W1 in first region D1 to facilitate installation space. They have a relatively large size W2 in second region D2, ensuring a large overlap between the positive and negative terminals. The positive and negative terminals of capacitor module 200 have a relatively small size W3 in third region D3 to facilitate installation space. They have a relatively large size W4 in fourth region D4, ensuring a large overlap between the positive and negative terminals. This arrangement maximizes the overlap between the positive and negative terminals while facilitating installation of power module 100 and capacitor module 200 within the external housing, thereby reducing the ESL of the current loop.

[0227] In this embodiment, the arrangement of the positive and negative terminals of the drive control module 110 and the power generation control module 120 in the power module 100, as well as the connection between each positive and negative terminal and the positive and negative terminal of the capacitor module 200, are similar to those in the previous embodiment. A one-to-one description is omitted.

[0228] like Figure 10 As shown, in this embodiment, the drive control module 110 and the power generation control module 120 of the power module 100 share the same capacitor module 200. This can improve the integration of the motor controller and help simplify the assembly process.

[0229] The present application also provides an electric drive assembly, which includes the motor controller described in the previous embodiment. This electric drive assembly also includes a generator motor and a drive motor. The drive control module 110 of the power module 100 is connected to the drive motor, and the power generation control module 120 is connected to the generator motor. This electric drive assembly has similar technical effects as the power module 100 described above and will not be repeated here.

[0230] The present application also provides a vehicle comprising the aforementioned electric drive assembly. In practical applications, the vehicle may be an extended-range vehicle, having independent motor drive requirements and independent power generation requirements. This vehicle utilizes the aforementioned electric drive assembly and achieves similar technical effects, which will not be repeated here. In other applications, the vehicle may also be other types of vehicles, not limited to extended-range vehicles.

[0231] In practical applications, the aforementioned power module 100, motor controller, and electric drive assembly can also be applied to other occasions with motor drive and power generation requirements, not limited to vehicles.

[0232] The ordinal numbers such as first and second used in this article are to distinguish different components with the same name, and do not indicate a specific order or a primary and secondary relationship.

[0233] This document uses specific examples to illustrate the principles and implementation methods of this application. The description of the above examples is only intended to help understand the method and core ideas of this application. It should be noted that for those skilled in the art, without departing from the principles of this application, various improvements and modifications can be made to this application, and such improvements and modifications also fall within the scope of protection of the claims of this application.

Claims

1. A power module, characterized in that: It comprises a plurality of sub-power modules, each of which corresponds to one phase, and at least two of the sub-power modules share the same pair of positive and negative terminals.

2. The power module according to claim 1, wherein: The at least two sub-power modules share a common liner.

3. The power module according to claim 1 or 2, characterized in that: At least two sub-power modules among the plurality of sub-power modules share a common liner.

4. The power module according to any one of claims 1 to 3, characterized in that: The power module includes a drive control module and a power generation control module; the drive control module includes at least one first sub-power module, the power generation control module includes at least one second sub-power module, and at least two of the second sub-power modules share the same pair of positive terminals and negative terminals.

5. The power module according to claim 4, characterized in that: At least one of the first sub-power modules has an independent liner.

6. The power module according to claim 4 or 5, characterized in that: The at least two second sub-power modules share a common backing plate.

7. The power module according to any one of claims 4 to 6, characterized in that: The driving control module includes three of the first sub-power modules, and the power generation control module includes three of the second sub-power modules.

8. The power module according to any one of claims 4 to 7, characterized in that: The at least one first sub-power module is arranged along the first direction, and / or the at least one second sub-power module is arranged along the first direction.

9. The power module according to claim 7 or 8, characterized in that: The three second sub-power modules share a common liner.

10. The power module according to any one of claims 1 to 9, characterized in that: At least one positive terminal or at least one negative terminal of the power module is configured to be connected to the same transfer terminal.

11. The power module according to any one of claims 2 to 10, characterized in that: The power module includes a first terminal and a second terminal, and projections of the first terminal and the second terminal on a plane where the backing plate is located at least partially overlap.

12. A motor controller, characterized in that The power module comprises the power module according to any one of claims 1 to 11.

13. Electric drive assembly, characterized in that, Including the motor controller described in claim 12.

14. A vehicle, characterized in that Including the electric drive assembly as described in claim 13.

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