Motor controller

Abstract

The invention relates to the technical field of controllers, in particular to a motor controller. A motor controller comprises a main box body, and a middle-layer box body is arranged in the middle of the main box body and divides the main box body into an upper box body and a lower box body; a bus capacitor, a first main drive power module, a second main drive power module and a power distribution module are arranged in the upper box body. The bus capacitor is electrically connected with the first main drive power module and the second main drive power module. A third main drive power module, a first auxiliary drive power module, a second auxiliary drive power module and a DCDC module are arranged in the lower box body, the third main drive power module is electrically connected with the bus capacitor, and the first auxiliary drive power module, the second auxiliary drive power module and the DCDC module are electrically connected with the power distribution module. The technical problems that in the prior art, a single motor controller cannot meet the multi-main-drive configuration requirement, the arrangement mode of multiple motor controllers can cause the high vehicle electric control cost, and large space in a vehicle needs to be occupied are solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of controllers, in particular to a motor controller. BACKGROUND

[0002] At present, the motor controllers on the market are mainly in the form of single motor controller, three-in-one or even four-in-one integration. Although the integration of part of the functions is realized to a certain extent, the overall integration level is still low, which is difficult to meet the increasingly complex multi-motor driving demand. Especially in the scene where multiple main drives and multiple auxiliary drives work, such as high-performance electric vehicles or special industrial transportation equipment, multiple independent motor controllers are usually deployed to correspond to different main drives and auxiliary drives. Although this scheme can realize the basic functions, it increases the cost of the vehicle's electric control system. At the same time, the installation of multiple controllers not only occupies a large amount of vehicle space, but also puts higher requirements on the vehicle wiring, heat dissipation structure and electromagnetic compatibility design, further increasing the system complexity and manufacturing difficulty. SUMMARY

[0003] In order to solve the technical problems that the single motor controller in the prior art cannot meet the multi-main drive configuration requirement, the setting mode of multiple motor controllers leads to high cost of vehicle electric control and needs to occupy a large space inside the vehicle, the present application provides a motor controller, which solves the above technical problems.

[0004] In order to solve the above technical problems, the present application provides a motor controller, comprising: a main box, a middle layer box is arranged in the middle part of the main box, so as to divide the main box into an upper box and a lower box; a bus capacitor, a first main drive power module, a second main drive power module and a power distribution module are arranged in the upper box, and the bus capacitor is electrically connected with the first main drive power module and the second main drive power module respectively; a third main drive power module, a first auxiliary drive power module, a second auxiliary drive power module and a DCDC module are arranged in the lower box, the third main drive power module is electrically connected with the bus capacitor, and the first auxiliary drive power module, the second auxiliary drive power module and the DCDC module are electrically connected with the power distribution module respectively.

[0005] According to an embodiment of the present application, positive and negative bus bars are arranged on both sides of the bus capacitor, a first positive connection end of the positive bus bar and a first negative connection end of the negative bus bar are arranged in a stack, and are electrically connected with the first main drive power module and the second main drive power module in the upper box respectively; a second positive connection end of the positive bus bar and a second negative connection end of the negative bus bar pass through the middle layer box and are electrically connected with the third main drive power module in the lower box.

[0006] According to one embodiment of the present application, the positive busbar comprises a positive busbar body and a first connecting part connected thereto, the first connecting part extends above the upper box along the positive busbar body, the first positive connecting end is arranged on the first connecting part, and the second positive connecting end is arranged on the first connecting part or the positive busbar body; the negative busbar comprises a negative busbar body and a second connecting part connected thereto, the second connecting part extends to the middle layer box along the negative busbar body, the first negative connecting end is arranged on the second connecting part or the negative busbar body, and the second negative connecting end is arranged on the second connecting part; a through hole is formed in the positive busbar body or the first connecting part, and the second negative connecting end is connected to the second connecting part through the through hole.

[0007] According to one embodiment of the present application, the power input end of the motor controller is arranged at a corner of the upper box, the positive and negative poles of the power input end are respectively electrically connected to the bus capacitor through the third positive connecting end of the positive busbar and the third negative connecting end of the negative busbar, and a reinforcing rib is arranged between the power module close to the power input end and the power input end.

[0008] According to one embodiment of the present application, the ports of the first main drive power module, the second main drive power module, the third main drive power module, the first auxiliary drive power module, the second auxiliary drive power module, the DCDC module and the power input end are located on the first side of the main box, wherein the ports of the first main drive power module, the second main drive power module, the third main drive power module, the first auxiliary drive power module and the second auxiliary drive power module are located on one side of the first side, and the ports of the DCDC module and the power input end are located on the other side of the first side.

[0009] According to one embodiment of the present application, further comprising: a double main drive integrated board arranged in the upper box and integrated with a signal switching board, a first main drive control board and a second main drive control board; a main auxiliary drive integrated board arranged in the lower box and integrated with a third main drive control board, a first auxiliary drive control board and a second auxiliary drive control board, and the double main drive integrated board and the main auxiliary drive integrated board are signal connected.

[0010] According to one embodiment of the present application, the double main drive integrated board and the first main drive power module and the second main drive power module of the upper box are provided with a first sheet metal tray, and the main auxiliary drive integrated board and the third main drive power module, the first auxiliary drive power module and the second auxiliary drive power module of the lower box are provided with a second sheet metal tray.

[0011] According to one embodiment of the present application, the first main drive power module drives a first main drive motor of the vehicle under the control of the double main drive integrated board; the second main drive power module drives a second main drive motor of the vehicle under the control of the double main drive integrated board; the third main drive power module drives an axle extension motor of the vehicle under the control of the main auxiliary drive integrated board; the first auxiliary drive power module drives a gas pump motor of the vehicle under the control of the main auxiliary drive integrated board; and the second auxiliary drive power module drives a steering motor of the vehicle under the control of the main auxiliary drive integrated board.

[0012] According to one embodiment of the present application, the power distribution module comprises a first fuse arranged between a power battery of the vehicle and the DCDC module, a second fuse arranged between the power battery and the first auxiliary drive power module, and a third fuse arranged between the power battery and the second auxiliary drive power module; the power distribution module further comprises an electric heating contactor, an electric defrosting contactor, and an upper-mounted contactor connected to the power battery respectively, the electric defrosting contactor and the electric heating contactor being connected to electric defrosting and electric heating of the vehicle through corresponding fuses respectively; the upper-mounted contactor is connected to an electric air conditioner of the vehicle through a sixth fuse, and is connected to a controllable power distribution of the vehicle through a seventh fuse.

[0013] According to one embodiment of the present application, the power distribution module further comprises a pre-charge module connected in parallel to the upper-mounted contactor, the pre-charge module comprising an upper-mounted pre-charge contactor and a pre-charge resistor connected in series.

[0014] According to one embodiment of the present application, the first to sixth fuses are accommodated in the same support seat, and an upper cover plate is further mounted on the upper box body, a maintenance window being formed in the upper cover plate and corresponding to the support seat.

[0015] According to one embodiment of the present application, a heat dissipation water channel is formed in the middle layer box body, and a first heat dissipation groove, a second heat dissipation groove, and a third heat dissipation groove are formed in the heat dissipation water channel and used for mounting the first main drive power module, the second main drive power module, and the third main drive power module respectively.

[0016] According to one embodiment of the present application, a heat dissipation column is arranged between the first heat dissipation groove and the third heat dissipation groove, cooling liquid entering the heat dissipation water channel is distributed through the heat dissipation column, flows through the first heat dissipation groove and the third heat dissipation groove respectively, and then converges at the communication between the third heat dissipation groove and the second heat dissipation groove and enters the second heat dissipation groove.

[0017] Based on the above technical solutions, the present application can achieve the following technical effects: 1. The motor controller of the present application, by setting the middle layer box to divide the main box into upper and lower boxes, and placing the first main drive power module, the second main drive power module and the power distribution module in the upper box, and placing the third main drive power module, the first auxiliary drive power module, the second auxiliary drive power module and the DCDC module in the lower box, realizing the seven-in-one configuration of three main drives, two auxiliary drives, one DCDC module and one power distribution module in the same motor controller, while comprehensively considering the factors of thermal management, module assembly, cost and maintainability, fully utilizing the internal space of the main box, the space utilization rate is higher, avoiding occupying a larger space inside the vehicle, reducing the cost of vehicle electric control; 2. By stacking the first positive connection end of the positive busbar and the first negative connection end of the negative busbar, and electrically connecting the first and second main drive power modules in the upper box; the second positive connection end of the positive busbar and the second negative connection end of the negative busbar pass through the middle layer box and are electrically connected with the third main drive power module in the lower box, realizing that three power modules share one bus capacitor, further improving the space utilization rate; 3. Further, a through hole is formed on the positive copper bar body or the first connecting part, so that the second negative connection end can pass through the through hole and be connected with the second connecting part, so that the second negative connection end and the second connecting part are connected without occupying other space outside the edge of the first connecting part and the second connecting part, to improve the space utilization rate; 4. The AC output port of the main drive power module and the auxiliary drive power module, and the DC power distribution port of the DCDC module and the power distribution module are separately arranged, reducing the EMC (Electromagnetic Compatibility) interference between AC output and DC power distribution; 5. Further, a first metal tray is arranged between the double main drive integrated board and the adjacent power module, and a second metal tray is arranged between the main auxiliary drive integrated board and the adjacent power module, so as to realize the isolation of the double main drive integrated board and the main auxiliary drive integrated board, to reduce the EMC interference; 6. By arranging a pre-charging module in parallel with the upper-mounted contactor, the stability of the circuit is improved by pre-charging protection for the upper-mounted contactor and the electric air conditioner to form an upper-mounted loop; 7. By concentrating the first to sixth fuses in the same support seat, and opening a maintenance window corresponding to the support seat on the upper cover plate, the damaged fuses can be replaced in time, and at the same time the space utilization rate of the upper box is improved; 8. By forming a heat dissipation water channel in the middle layer box, opening a heat dissipation groove for installing the main drive power module on the heat dissipation water channel, and further arranging a heat dissipation column between the first heat dissipation groove and the third heat dissipation groove, so that the cooling liquid enters the heat dissipation water channel, is distributed through the heat dissipation column, and then flows through the first heat dissipation groove and the third heat dissipation groove respectively, and then converges at the communication between the third heat dissipation groove and the second heat dissipation groove, and enters the second heat dissipation groove, so as to reduce the mutual interference between different main drive power modules, and by adjusting the size of the heat dissipation column, the flow distribution between the first heat dissipation groove and the third heat dissipation groove can be adjusted, so as to ensure the uniform heat dissipation between the main drive power modules. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1 The spatial layout schematic diagram of the motor controller of the embodiment of the application is shown in the figure. Figure 2 The layout schematic diagram of the main drive power module in the upper box is shown in the figure. Figure 3 The layout schematic diagram of the main drive power module in the lower box is shown in the figure. Figure 4 The layout schematic diagram of the upper box is shown in the figure. Figure 5 The layout schematic diagram of the lower box is shown in the figure. Figure 6 The front view of the motor controller is shown in the figure. Figure 7 The exploded view of the motor controller is shown in the figure. Figure 8 The structure schematic diagram of the bus capacitor and the positive busbar and the negative busbar on both sides of the bus capacitor is shown in the figure. Figure 9 The matching relationship schematic diagram of the positive busbar and the negative busbar is shown in the figure. Figure 10 The circuit topology diagram of the motor controller is shown in the figure. Figure 11 The structure schematic diagram of the heat dissipation water channel is shown in the figure. Figure 12 The cross-sectional view of the heat dissipation water channel is shown in the figure.

[0019] In the figure: 1 - middle layer box; 11 - reinforcing rib; 12 - heat dissipation water channel; 121 - first heat dissipation groove; 122 - second heat dissipation groove; 123 - third heat dissipation groove; 124 - heat dissipation column; 125 - liquid inlet; 126 - liquid outlet; 2 - upper box; 21 - bus capacitor; 22 - first main drive power module; 23 - second main drive power module; 24 - power distribution module; 241 - first fuse; 242 - second fuse; 243 - third fuse; 244 - electric heating contactor; 245 - electric defrosting contactor; 246 - upper-mounted contactor; 247 - fourth fuse; 248 - fifth fuse; 249 - sixth fuse; 240 - seventh fuse; 25 - positive busbar; 251 - first positive connection end; 252 - second positive connection end; 253 - positive busbar body; 254 - first connecting part; 255 - through hole; 256 - third positive connection end; 26 - negative busbar; 261 - first negative connection end; 262 - second negative connection end; 263 - negative busbar body; 264 - second connecting part; 265 - third negative connection end; 27 - power input end; 28 - double main drive integrated board; 281 - first sheet metal tray; 29 - pre-charging module; 291 - upper-mounted pre-charging contactor; 292 - pre-charging resistor; 3 - lower box; 31 - third main drive power module; 32 - first auxiliary drive power module; 33 - second auxiliary drive power module; 34 - DCDC module; 35 - main and auxiliary drive integrated board; 351 - second sheet metal tray; 4 - upper cover plate; 41 - maintenance window; 42 - maintenance cover plate; 5 - lower cover plate. DETAILED DESCRIPTION

[0020] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. The description of the at least one exemplary embodiment is actually only illustrative, but not intended to limit the present application and its application or use in any way. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative labor fall within the scope of the present application.

[0021] It should be noted that the terms used herein are only intended to describe specific embodiments, and are not intended to limit the exemplary embodiments according to the present application. As used herein, the singular form is intended to include the plural form, unless the context clearly indicates otherwise, and furthermore, it should be understood that when the terms "comprise" and / or "include" are used in the specification, there is a feature, step, operation, device, component and / or combination thereof.

[0022] The foregoing is considered as illustrative only of the principles of the application. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the application to the exact construction and practice described. Accordingly, all such variations are intended to be included within the scope of the present application as defined in the following claims, along with full equivalents thereof.

[0023] In the description of the present application, it is to be understood that the orientation or positional relationships indicated by terms such as "front", "back", "up", "down", "left", "right", "lateral", "vertical", "horizontal", "top", "bottom", and the like are generally based on the orientation or positional relationships shown in the drawings, and are merely intended to facilitate the description and simplify the description, and do not indicate or imply that the device or element referred to must have a particular orientation or be constructed and operated in a particular orientation, and therefore cannot be construed as limiting the scope of protection of the present application. The orientation terms "inner", "outer" refer to the inner and outer relative to the contour of the components themselves.

[0024] For the convenience of description, spatial relative terms such as "over", "above", "upper surface", "upper", and the like can be used herein to describe the spatial positional relationship of one device or feature with respect to other devices or features as shown in the drawings. It should be understood that the spatial relative terms are intended to include different orientations in use or operation in addition to the orientation of the device as described in the drawings. For example, if the device in the drawings is inverted, the device described as "above" or "over" other devices or structures will be positioned "below" or "under" the other devices or structures. Thus, the exemplary term "above" can include both "above" and "below" orientations. The device can also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein are interpreted accordingly.

[0025] In addition, it should be noted that the use of the terms "first", "second", and the like do not have a special meaning, and are used only to facilitate the distinction between corresponding parts, and therefore cannot be construed as limiting the scope of protection of the present application.

[0026] As Figures 1 to 7As shown, the embodiment provides a motor controller, comprising: a main box, wherein a middle layer box 1 is arranged in the middle part, so as to divide the main box into an upper box 2 and a lower box 3; the upper box 2 is provided with a bus capacitor 21, a first main drive power module 22, a second main drive power module 23 and a power distribution module 24, and the bus capacitor 21 is electrically connected with the first main drive power module 22 and the second main drive power module 23 respectively; the lower box 3 is provided with a third main drive power module 31, a first auxiliary drive power module 32, a second auxiliary drive power module 33 and a DCDC module 34, the third main drive power module 31 is electrically connected with the bus capacitor 21, and the first auxiliary drive power module 32, the second auxiliary drive power module 33 and the DCDC module 34 are electrically connected with the power distribution module 24 respectively, so as to realize the distribution of the external power supply. Wherein, the main drive power module can adopt the SiC (Silicon Carbide, Silicon Carbide) power module of HPD (High Power Device, High Power Device) packaging, or other types of power modules can be selected according to actual needs, and the embodiment does not limit it.

[0027] The motor controller of the embodiment of the application divides the main box into the upper box 2 and the lower box 3 by arranging the middle layer box 1, and places the first main drive power module 22, the second main drive power module 23 and the power distribution module 24 in the upper box 2, and places the third main drive power module 31, the first auxiliary drive power module 32, the second auxiliary drive power module 33 and the DCDC module 34 in the lower box 3, so as to realize the seven-in-one configuration of three main drives, two auxiliary drives, one DCDC module 34 and one power distribution module 24 in the same motor controller. While comprehensively considering the factors of heat management, module assembly, cost and maintainability, the internal space of the main box is fully utilized, the space utilization rate is high, the occupation of the internal space of the vehicle is avoided, and the electric control cost of the vehicle is reduced.

[0028] Specifically, as shown in Figure 2 and Figure 3 , the first main drive power module 22 and the second main drive power module 23 can be arranged above the middle layer box 1, and the third main drive power module 31 can be arranged on the opposite side of the corresponding position of the middle layer box 1, so as to facilitate the electrical connection and sharing of the heat dissipation module suitable for being arranged in the middle layer box 1; as shown in Figure 4 , the power distribution module 24 can be arranged at a position close to the outer side of the main box in the upper box 2, so as to facilitate the later maintenance; since the first main drive power module 22, the second main drive power module 23 and the DCDC module 34 have large sizes, and the upper box 2 is also provided with the power distribution module 24, the DCDC module 34 can be arranged on one side of the third main drive power module 31 close to the power distribution module 24 in the lower box 3, and then the first auxiliary drive power module 32 and the second auxiliary drive power module 33 can be placed in other idle positions around the third main drive power module 31, as shown in Figure 5 ​

[0029] As Figure 8 and Figure 9 shown, in one embodiment of the present application, the bus capacitor 21 can be provided with a positive busbar 25 and a negative busbar 26 on both sides, respectively, the first positive connection end 251 of the positive busbar 25 and the first negative connection end 261 of the negative busbar 26 are laminated, and are respectively electrically connected with the first main drive power module 22 and the second main drive power module 23 in the upper box body 2; the second positive connection end 252 of the positive busbar 25 and the second negative connection end 262 of the negative busbar 26 are connected with the third main drive power module 31 in the lower box body 3 through the middle layer box body 1, so as to realize the layout design of three power modules sharing one bus capacitor 21. The area where the positive busbar 25 and the negative busbar 26 are laminated can be provided with an insulating sheet or an insulating film, so as to realize electrical isolation.

[0030] Specifically, the positive busbar 25 can include a positive busbar body 253 and a first connecting part 254 connected with each other, the positive busbar body 253 can be arranged on the side of the bus capacitor 21 close to the middle layer box body 1, the first connecting part 254 extends upwards above the upper box body 2 along the positive busbar body 253, the first positive connection end 251 can be arranged on the first connecting part 254, and the second positive connection end 252 can be arranged on the first connecting part 254 or the positive busbar body 253; the negative busbar 26 can include a negative busbar body 263 and a second connecting part 264 connected with each other, the negative busbar body 263 can be arranged on the side of the bus capacitor 21 away from the middle layer box body 1, the second connecting part 264 extends towards the middle layer box body 1 along the negative busbar body 263, the first negative connection end 261 can be arranged on the second connecting part 264 or the negative busbar body 263, and the second negative connection end 262 can be arranged on the second connecting part 264.

[0031] Preferably, a through hole 255 can be formed on the positive busbar body 253 or the first connecting part 254, so that the second negative connection end 262 can pass through the through hole 255 and be connected with the second connecting part 264, so that when the second negative connection end 262 is connected with the second connecting part 264, no other space outside the edges of the first connecting part 254 and the second connecting part 264 is occupied, so as to improve the space utilization. In some other embodiments of the present application, structures for connecting the second negative connection end 262 and the second connecting part 264 can also be specially arranged, and the present embodiment is not limited thereto.

[0032] As Figure 2 , Figure 4 and Figure 7As shown in the figure, in one embodiment of the application, the power input end 27 of the motor controller is arranged at a corner of the upper box body 2, the positive and negative poles of the power input end 27 are respectively electrically connected with the bus capacitor 21 through the third positive pole connecting end 256 of the positive busbar 25 and the third negative pole connecting end 265 of the negative busbar 26, so that the external DC power supply is connected with the bus capacitor 21 through the power input end 27, and the power distribution module 24 in the upper box body 2 can also be connected with the external DC power supply through the power input end 27.

[0033] In one embodiment of the application, a reinforcing rib 11 is arranged between the power module close to the power input end 27 and the power input end 27, so as to isolate the power input end 27 of the motor controller from the power module and reduce the interference between AC and DC.

[0034] As shown in the figure, Figure 6 and Figure 7 As shown in the figure, in one embodiment of the application, the ports (U1, V1, W1) of the first main drive power module 22, the ports (U2, V2, W2) of the second main drive power module 23, the ports (U3, V3, W3) of the third main drive power module 31, the port "air compressor" of the first auxiliary drive power module 32, the port "steering" of the second auxiliary drive power module 33, the ports (DC-, DC+) of the DCDC module 34 and the ports (-battery-, +battery+) of the power input end 27 are located on the first side of the main box body, wherein the ports of the first main drive power module 22, the second main drive power module 23, the third main drive power module 31, the first auxiliary drive power module 32 and the second auxiliary drive power module 33 are located on one side of the first side, and the ports of the DCDC module 34 and the power input end 27 are located on the other side of the first side, so as to separately arrange the AC output ports of the main drive power module and the auxiliary drive power module and the DC power distribution ports of the DCDC module 34 and the power distribution module 24, so as to reduce the mutual interference between AC output and DC power distribution.

[0035] Specifically, the first main drive power module 22, the second main drive power module 23 and the third main drive power module 31 can be connected with the ports corresponding to the first side of the main box body through copper bars to realize external output, and the first auxiliary drive power module 32, the second auxiliary drive power module 33, the DCDC module 34 and the power input end 27 can be connected with the ports corresponding to the first side of the main box body through plug-in connectors, in some other embodiments of the application, the connection mode of the ports can also be adjusted according to actual needs, and the present embodiment is not limited in this way.

[0036] As shown in the figure, Figure 3 and Figure 4As shown, in one embodiment of the present invention, the motor controller may further include: a dual main drive integrated board 28 disposed in the upper housing 2 and a main auxiliary drive integrated board 35 disposed in the lower housing 3. The dual main drive integrated board 28 integrates a signal conversion board, a first main drive control board and a second main drive control board, and is used for signal conversion, sending control signals to the first main drive power module 22, sending control signals to the second main drive power module 23, etc. The main auxiliary drive integrated board 35 integrates a third main drive control board, a first auxiliary drive control board and a second auxiliary drive control board, and is used for sending control signals to the third main drive power module 31, sending control signals to the first auxiliary drive power module 32, sending control signals to the second auxiliary drive power module 33, etc. The dual main drive integrated board 28 and the main auxiliary drive integrated board 35 can be connected by a wiring harness.

[0037] In one embodiment of the present invention, a first sheet metal tray 281 is provided between the dual main drive integrated board 28 and the first main drive power module 22 and the second main drive power module 23 of the upper housing 2, and a second sheet metal tray 351 is provided between the main auxiliary drive integrated board 35 and the third main drive power module 31, the first auxiliary drive power module 32 and the second auxiliary drive power module 33 of the lower housing 3, thereby achieving isolation between the dual main drive integrated board 28 and the main auxiliary drive integrated board 35 to reduce EMC interference.

[0038] like Figure 10 As shown, in one embodiment of the present invention, the first main drive power module 22 drives the vehicle's first main drive motor under the control of the dual main drive integrated board 28; the second main drive power module 23 drives the vehicle's second main drive motor under the control of the dual main drive integrated board 28; the third main drive power module 31 drives the vehicle's axle extension motor under the control of the main and auxiliary drive integrated board 35; the first auxiliary drive power module 32 drives the vehicle's air pump motor under the control of the main and auxiliary drive integrated board 35; and the second auxiliary drive power module 33 drives the vehicle's steering motor under the control of the main and auxiliary drive integrated board 35.

[0039] In one embodiment of the present invention, the power distribution module 24 may include: a first fuse 241, a second fuse 242 and a third fuse 243, wherein the first fuse 241 is disposed between the vehicle's power battery and the DC-DC module 34; the second fuse 242 is disposed between the power battery and the first auxiliary drive power module 32; and the third fuse 243 is disposed between the power battery and the second auxiliary drive power module 33, so as to realize short-circuit protection for the DC-DC circuit, the first auxiliary drive (air pump) circuit and the second auxiliary drive (steering) circuit.

[0040] The power distribution module 24 further comprises an electric heating contactor 244, an electric defrosting contactor 245, an upper installation contactor 246, a fourth fuse 247, a fifth fuse 248, a sixth fuse 249 and a seventh fuse 240 connected to the power battery respectively, the electric heating contactor 244 and the electric defrosting contactor 245 are connected to the electric heating and the electric defrosting of the vehicle through the corresponding fourth fuse 247 and the fifth fuse 248 respectively, the upper installation contactor 246 is connected to the electric air conditioner of the vehicle through the sixth fuse 249, and the upper installation contactor 246 is connected to the controllable power distribution of the vehicle through the seventh fuse 240, so as to realize short circuit protection of each circuit.

[0041] In an embodiment of the present application, the power distribution module 24 further comprises a pre-charging module 29 connected in parallel to the upper installation contactor 246, the pre-charging module 29 comprises a pre-charging contactor 291 and a pre-charging resistor 292 connected in series, so as to realize pre-charging protection for the upper installation circuit formed by the electric air conditioner and the upper installation contactor 246.

[0042] As shown in Figure 4 and Figure 7 In an embodiment of the present application, the first to sixth fuses are accommodated in the same support seat, and an upper cover plate 4 is further installed on the upper box body 2, and a maintenance window 41 is formed on the upper cover plate 4, and the position of the maintenance window 41 corresponds to the support seat. Since the vulnerable parts in the motor controller are mainly the fuses, by accommodating all the fuses in the same support seat and forming the maintenance window 41 corresponding to the support seat on the upper cover plate 4, the damaged fuses can be replaced in time, and the space utilization of the upper box body 2 is improved. A maintenance cover plate 42 can be further arranged on the maintenance window 41 to play a protection role, and a lower cover plate 5 can also be arranged on the lower box body 3 to play a dustproof role.

[0043] Specifically, the fuses and contactors in the power distribution module 24 can be connected to the corresponding components through the adapter copper bars and wire harnesses, the adapter copper bars can be arranged below the support seat based on the structural design of the support seat, away from the main drive power module, so as to reduce the EMC interference; the electric heating contactor 244, the electric defrosting contactor 245, the upper installation contactor 246, the pre-charging resistor 292 and the power distribution interface can be arranged on the side of the bus capacitor 21, which is beneficial to reducing the length of the wire harnesses, saving costs, and avoiding the influence of the power module EMC through the wiring mode.

[0044] As shown in Figure 11 and Figure 12As shown in the drawings, in one embodiment of the present application, the middle layer box body 1 can be formed with a heat dissipation water channel 12, the heat dissipation water channel 12 is provided with a first heat dissipation groove 121, a second heat dissipation groove 122 and a third heat dissipation groove 123, which are respectively used for mounting the first main drive power module 22, the second main drive power module 23 and the third main drive power module 31, so that the cooling liquid can directly cool the first main drive power module 22, the second main drive power module 23 and the third main drive power module 31 in the heat dissipation water channel 12, compared with specially configuring a heat dissipation module for each main drive power module, the cost is lower and the heat dissipation efficiency is higher.

[0045] In one embodiment of the present application, a heat dissipation column 124 is arranged between the first heat dissipation groove 121 and the third heat dissipation groove 123, the cooling liquid entering the heat dissipation water channel 12 is divided by the heat dissipation column 124, and then flows through the first heat dissipation groove 121 and the third heat dissipation groove 123 respectively, and then converges at the communication between the third heat dissipation groove 123 and the second heat dissipation groove 122 and enters the second heat dissipation groove 122, so as to reduce the mutual interference between different main drive power modules, and by adjusting the size of the heat dissipation column 124, the flow distribution between the first heat dissipation groove 121 and the third heat dissipation groove 123 can be adjusted, so as to ensure the uniform heat dissipation between the main drive power modules.

[0046] Preferably, the width of the heat dissipation water channel at the convergence of the first heat dissipation groove, the third heat dissipation groove 123 and the second heat dissipation groove 122 is greater than the gap between the heat dissipation column and the first heat dissipation groove and the third heat dissipation groove, so as to avoid the flow rate surge caused by the flow superposition after the convergence of the cooling liquid from the first heat dissipation groove and the third heat dissipation groove, and ensure the uniform heat dissipation of the main drive power modules.

[0047] As shown in the drawings, Figure 4 and 7 As shown in the drawings, in one embodiment of the present application, the heat dissipation water channel 12 can include a liquid inlet water channel and a liquid outlet water channel connected together, the liquid inlet water channel is provided with the heat dissipation grooves described above, the liquid inlet 125 of the liquid inlet water channel and the liquid outlet 126 of the liquid outlet water channel are located on the second side of the main box body, realizing the same side inlet and outlet of the cooling liquid, and the cooling liquid flowing out of the liquid outlet water channel can also cool the components on both sides of the liquid outlet water channel, realizing the full utilization of the cooling liquid.

[0048] The embodiments of the present application are described in detail above in combination with the drawings, but the present application is not limited to the above-mentioned embodiments, and various changes can be made within the knowledge of those skilled in the art without departing from the spirit of the present application.

Claims

1. A motor controller, characterized in that, include: The main box has a middle box (1) in the middle, which divides the main box into an upper box (2) and a lower box (3). The upper housing (2) is equipped with a bus capacitor (21), a first main drive power module (22), a second main drive power module (23) and a power distribution module (24). The bus capacitor (21) is electrically connected to the first main drive power module (22) and the second main drive power module (23) respectively. The lower housing (3) is equipped with a third main drive power module (31), a first auxiliary drive power module (32), a second auxiliary drive power module (33), and a DC-DC module (34). The third main drive power module (31) is electrically connected to the bus capacitor (21), and the first auxiliary drive power module (32), the second auxiliary drive power module (33), and the DC-DC module (34) are electrically connected to the power distribution module (24).

2. The motor controller according to claim 1, characterized in that, The bus capacitor (21) is provided with a positive busbar (25) and a negative busbar (26) on both sides respectively. The first positive terminal (251) of the positive busbar (25) and the first negative terminal (261) of the negative busbar (26) are stacked and electrically connected to the first main drive power module (22) and the second main drive power module (23) respectively in the upper box (2). The second positive terminal (252) of the positive busbar (25) and the second negative terminal (262) of the negative busbar (26) pass through the middle box (1) and are electrically connected to the third main drive power module (31) in the lower box (3).

3. The motor controller according to claim 2, characterized in that, The positive busbar (25) includes a connected positive busbar body (253) and a first connecting part (254). The first connecting part (254) extends upward along the positive busbar body (253) to the upper housing (2). The second positive connecting end (252) is disposed on the first connecting part (254) or the positive busbar body (253). The negative busbar (26) includes a connected negative busbar body (263) and a second connecting part (264). The second connecting part (264) extends along the negative busbar body (263) to the middle housing (1). A through hole (255) is opened on the positive busbar body (253) or the first connecting part (254). The second negative connecting end (262) passes through the through hole (255) and connects to the second connecting part (264).

4. The motor controller according to claim 2, characterized in that, The power input terminal (27) of the motor controller is located at one corner of the upper housing (2). The positive and negative terminals of the power input terminal (27) are electrically connected to the bus capacitor (21) through the third positive terminal (256) of the positive busbar (25) and the third negative terminal (265) of the negative busbar (26), respectively. A reinforcing rib (11) is provided between the power module near the power input terminal (27) and the power input terminal (27).

5. The motor controller according to claim 4, characterized in that, The ports of the first main drive power module (22), the second main drive power module (23), the third main drive power module (31), the first auxiliary drive power module (32), and the second auxiliary drive power module (33) are located on one side of the first side of the main housing, and the ports of the DC-DC module (34) and the power input terminal (27) are located on the other side of the first side.

6. The motor controller according to claim 1, characterized in that, Also includes: The dual main drive integrated board (28) is located inside the upper housing (2), and integrates a signal adapter board, a first main drive control board and a second main drive control board. The main and auxiliary drive integrated board (35) is located in the lower housing (3), which integrates a third main drive control board, a first auxiliary drive control board and a second auxiliary drive control board, and the dual main drive integrated board (28) and the main and auxiliary drive integrated board (35) are connected by signals.

7. The motor controller according to claim 6, characterized in that, A first sheet metal tray (281) is provided between the dual main drive integrated board (28) and the first main drive power module (22) and the second main drive power module (23) of the upper housing (2), and a second sheet metal tray (351) is provided between the main and auxiliary drive integrated board (35) and the third main drive power module (31), the first auxiliary drive power module (32), and the second auxiliary drive power module (33) of the lower housing (3).

8. The motor controller according to claim 6, characterized in that, The first main drive power module (22) drives the vehicle's first main drive motor under the control of the dual main drive integrated board (28); the second main drive power module (23) drives the vehicle's second main drive motor under the control of the dual main drive integrated board (28); the third main drive power module (31) drives the vehicle's axle extension motor under the control of the main and auxiliary drive integrated board (35); the first auxiliary drive power module (32) drives the vehicle's air pump motor under the control of the main and auxiliary drive integrated board (35); and the second auxiliary drive power module (33) drives the vehicle's steering motor under the control of the main and auxiliary drive integrated board (35).

9. The motor controller according to claim 8, characterized in that, The power distribution module (24) includes: a first fuse (241) disposed between the vehicle's power battery and the DC-DC module (34); a second fuse (242) disposed between the power battery and the first auxiliary drive power module (32); and a third fuse (243) disposed between the power battery and the second auxiliary drive power module (33). The power distribution module (24) also includes an electric heating contactor (244), an electric defrosting contactor (245), and an upper structure contactor (246) that are respectively connected to the power battery. The electric heating contactor (244) and the electric defrosting contactor (245) are respectively connected to the electric heating and electric defrosting of the vehicle through a fourth fuse (247) and a fifth fuse (248). The upper structure contactor (246) is connected to the electric air conditioning of the vehicle through a sixth fuse (249), and the upper structure contactor (246) is connected to the controllable power distribution of the vehicle through a seventh fuse (240).

10. The motor controller according to claim 9, characterized in that, The power distribution module (24) also includes a pre-charge module (29) connected in parallel with the upper contactor (246). The pre-charge module (29) includes an upper pre-charge contactor (291) and a pre-charge resistor (292) connected in series.

11. The motor controller according to claim 9, characterized in that, The first to sixth fuses are housed in the same support base. The upper housing (2) is also equipped with an upper cover plate (4). The upper cover plate (4) has a maintenance window (41) which is located opposite to the support base.

12. The motor controller according to claim 1, characterized in that, The middle layer box (1) has a heat dissipation channel (12) formed inside. The heat dissipation channel (12) has a first heat dissipation slot (121), a second heat dissipation slot (122) and a third heat dissipation slot (123) for installing the first main drive power module (22), the second main drive power module (23) and the third main drive power module (31), respectively.

13. The motor controller according to claim 12, characterized in that, A heat dissipation column (124) is provided between the first heat dissipation tank (121) and the third heat dissipation tank (123). After the coolant enters the heat dissipation channel (12) and is divided by the heat dissipation column (124), it flows through the first heat dissipation tank (121) and the third heat dissipation tank (123) respectively. Then it merges at the connection between the third heat dissipation tank (123) and the second heat dissipation tank (122) and enters the second heat dissipation tank (122).

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