Motor controller assembly, motor controller assembly mounting structure and vehicle

Abstract

The invention discloses a motor controller assembly, a motor controller assembly mounting structure and a vehicle, the motor controller assembly comprises a controller shell and a power module assembly, an accommodating cavity is formed in the controller shell, a shell liquid outlet and a shell liquid inlet are formed in the controller shell, and the power module assembly is arranged in the accommodating cavity. The containing cavity is provided with an opening used for being in butt joint with a motor shell. At least part of the power module assembly is arranged in the accommodating cavity, and a liquid cooling inlet, a built-in cooling flow channel and a liquid cooling outlet are formed in the power module assembly; wherein the shell liquid outlet, the liquid cooling liquid inlet, the built-in cooling flow channel, the liquid cooling liquid outlet and the shell liquid inlet are in fluid communication in sequence, and sealing structures are arranged at the butt joint of the shell liquid outlet and the liquid cooling liquid inlet and the butt joint of the shell liquid inlet and the liquid cooling liquid outlet. The structure is simple, the number of sealing positions is small, the area needing to be sealed is small, the space utilization rate can be increased, and the weight and cost are both reduced.

Description

Technical Field

[0001] This invention relates to vehicle electric drive systems, specifically to a motor controller assembly, a motor controller assembly mounting structure, and a vehicle. Background Technology

[0002] With the rapid development of new energy vehicles, electric drive systems are gradually becoming smaller and lighter, with increasingly higher levels of integration. The more integrated multi-in-one electric drive system is a key development direction for major new energy vehicle manufacturers. This system integrates three core components: the motor assembly, the motor controller assembly, and the reducer assembly. The motor controller assembly, as an independent and enclosed component, is typically directly mounted on the motor housing or reducer housing. It generally includes the motor controller housing, upper cover, lower cover, and other components, resulting in a complex structure, numerous seals, and a large sealing area, weight, and volume. Summary of the Invention

[0003] In view of this, the purpose of the present invention is to provide a motor controller assembly, a motor controller assembly mounting structure, and a vehicle, which has a simple structure, fewer sealing points and a small sealing area, and can also increase space utilization. The weight and cost of the motor controller assembly are reduced.

[0004] A motor controller assembly according to the present invention includes: The controller housing has an internal cavity and is provided with a liquid outlet and a liquid inlet. The cavity has an opening for docking with the motor housing. And a power module assembly, which is at least partially disposed within the receiving cavity, and is provided with a liquid cooling inlet, an internal cooling channel and a liquid cooling outlet; The liquid outlet of the housing, the liquid cooling inlet, the built-in cooling channel, the liquid cooling outlet, and the liquid inlet of the housing are sequentially connected in fluid communication, and a sealing structure is provided at the junction of the liquid outlet of the housing and the liquid cooling inlet, and at the junction of the liquid inlet of the housing and the liquid cooling outlet.

[0005] Furthermore, the controller housing is provided with a first mating end face on the outside corresponding to the liquid outlet and liquid inlet of the housing, and the power module assembly is provided with a second mating end face at the position corresponding to the first mating end face, and a first sealing ring is provided between the first mating end face and the corresponding second mating end face.

[0006] Furthermore, a first mounting groove is provided on the first mating end face, surrounding the liquid outlet or liquid inlet of the housing. After the first mating end face abuts against the corresponding second mating end face, the first sealing ring is pressed into the first mounting groove.

[0007] Furthermore, the controller housing is provided with an electrically controlled liquid inlet and an electrically controlled liquid outlet, both of which are located outside the receiving cavity. The electrically controlled liquid inlet is used to communicate with an external coolant pipeline, and the electrically controlled liquid outlet is used to communicate with the motor cooling liquid inlet of the motor housing. The electrically controlled liquid inlet and the housing liquid outlet are connected through a first internal flow channel of the controller housing, and the housing liquid inlet and the electrically controlled liquid outlet are connected through a second internal flow channel of the controller housing.

[0008] Furthermore, the controller housing includes a housing base plate and housing side plates surrounding the outer edge of the housing base plate; the housing side plates are provided with a pipe interface, the pipe interface being hollow inside to form the electronically controlled liquid inlet; the housing side plates are provided with a flange for docking with the motor housing, the flange being provided with a docking frustum, the docking frustum being hollow inside to form the electronically controlled liquid outlet.

[0009] Furthermore, the power module assembly includes a drive and control integrated board, an IGBT module, a liquid cooling component, and a thin-film capacitor arranged sequentially along a first direction. The IGBT module is equipped with a current sensor. The IGBT module is located on the side of the liquid cooling component facing the opening. The thin-film capacitor is located on the side of the liquid cooling component facing away from the opening. A thermal pad is provided between the side of the thin-film capacitor facing away from the opening and the controller housing. The first direction is the direction along the opening pointing towards the bottom plate of the controller housing.

[0010] Furthermore, the liquid cooling inlet, the built-in cooling channel, and the liquid cooling outlet are all disposed on the liquid cooling component. The liquid cooling component has a cooling contact surface on the outside corresponding to the built-in cooling channel, and the cooling contact surface is in contact with the IGBT module. The liquid cooling component is provided with a frame structure, and the frame structure is provided with multiple clearance through holes. The multiple first copper busbars of the thin film capacitor pass through each of the clearance through holes and are connected to the multiple second copper busbars of the IGBT module. The liquid cooling component is provided with an integrated plate connection structure, an IGBT connection structure, a capacitor connection structure, and a housing connection structure.

[0011] Furthermore, the integrated drive and control board is provided with a low-voltage connector, the controller housing is provided with a through hole for the low-voltage connector to pass through, the controller housing is provided with a sealing baffle at the position between the through hole and the receiving cavity, the sealing baffle protrudes from the controller housing; the controller housing is also provided with a detachable junction box cover.

[0012] The present invention provides a motor controller assembly mounting structure, including a motor housing and the aforementioned motor controller assembly; the motor housing is provided with an annular docking structure, which docks with the opening of the receiving cavity of the controller housing to form a closed cavity for accommodating the power module assembly.

[0013] A vehicle according to the present invention includes the above-described motor controller assembly mounting structure.

[0014] The beneficial effects of this invention are: (1) No water pipe joint or water nozzle is required between the power module assembly and the controller housing of the present invention, which can shorten the coolant flow path between the power module assembly and the controller housing, reduce flow resistance, and facilitate the cooling of the motor controller assembly. Furthermore, there are only two docking points between the power module assembly and the controller housing, and a sealing structure can be set on the contact surface of the two docking points. The structure is simple, the number of sealing points is small, and the area to be sealed is small.

[0015] (2) The motor controller assembly of the present invention is designed in a semi-open state, which does not require separate sealing of the cavity. The opening of the cavity is directly connected to the motor housing for sealing, further reducing the number of sealing points of the motor controller assembly, eliminating the traditional upper and lower cover closed structure of the motor controller assembly, increasing space utilization, and reducing the weight and cost of the motor controller assembly.

[0016] (3) The sealing structure of the present invention is simple and low in cost, and easy to operate during installation.

[0017] (4) The electronically controlled liquid inlet and the electronically controlled liquid outlet of the present invention are both located outside the receiving cavity, so that the connection between the electronically controlled liquid inlet and the external coolant pipeline, and the connection between the electronically controlled liquid outlet and the motor cooling liquid inlet of the motor housing are both located outside the receiving cavity, thereby preventing damage to the components inside the receiving cavity when coolant leaks at these two connection points.

[0018] (5) The thermal pad of the present invention is pressed and fixed between the thin film capacitor and the controller housing. The thin film capacitor transfers heat to the controller housing through the thermal pad, and the controller housing dissipates the heat to the external environment, thereby cooling the thin film capacitor. The liquid cooling component is in contact with the IGBT module. The IGBT module transfers heat to the liquid cooling component, and the heat is carried away by the coolant flowing inside the liquid cooling component, thereby cooling the IGBT module.

[0019] (6) The power module assembly of the present invention has a compact structure, which can improve space utilization. Furthermore, the reasonable installation structure makes the assembly of the motor controller assembly simple. At the same time, the liquid cooling component has no electronic components, and using the liquid cooling component as the base of the power module assembly can also make the structure more stable.

[0020] (7) The controller housing of the present invention is provided with a detachable junction box cover. During assembly, inspection and maintenance, and after-sales maintenance, it is necessary to remove the detachable junction box cover to operate the electronic components and wiring harness in the cavity. After the assembly, inspection and maintenance are completed, the detachable junction box cover is installed to close the window of the side plate of the controller housing, which can prevent dust and rainwater from entering the cavity. Attached Figure Description

[0021] To make the objectives, technical solutions, and beneficial effects of this invention clearer, the following figures are provided for illustration: Figure 1 This is an exploded view of the motor controller assembly of the present invention; Figure 2 This is a cross-sectional schematic diagram of the motor controller assembly of the present invention; Figure 3 This is an exploded view of the power module assembly of the present invention; Figure 4 This is an exploded view of the motor controller assembly and the motor housing of the present invention.

[0022] The following labels are shown in the attached diagram: 100-Controller housing, 101-Receiving cavity, 102-Housing outlet, 103-Housing inlet, 104-First mating end face, 105-First sealing ring, 106-Electrically controlled inlet, 107-Electrically controlled outlet, 108-First internal flow channel, 109-Second internal flow channel, 110-Housing base plate, 111-Housing side plate, 112-Pipe interface, 113-Flange flange, 114-Mating frustum, 115-Through hole, 116-Sealing baffle, 117-Removable junction box cover; 200-Power module assembly, 210-Drive and control integrated board, 220-IGBT module, 221-Second copper busbar, 230-Liquid cooling component, 231-Liquid cooling inlet, 232-Built-in cooling channel, 233-Liquid cooling outlet, 234-Cooling contact surface, 235-Frame structure, 236-Integrated board connection structure, 237-IGBT connection structure, 238-Capacitor connection structure, 239-Housing connection structure, 240-Film capacitor, 241-First copper busbar, 250-Current sensor, 260-Thermal pad, 270-Low-voltage connector; 300 - Motor housing, 301 - Motor cooling inlet, 302 - Annular docking structure, 303 - Second sealing ring. Detailed Implementation

[0023] The technical solution of the present invention will be described in detail below with reference to the accompanying drawings and embodiments.

[0024] like Figures 1-4As shown, a motor controller assembly in this embodiment includes a controller housing 100 and a power module assembly 200. The controller housing 100 has an internal cavity 101, and the controller housing 100 is provided with a housing liquid outlet 102 and a housing liquid inlet 103. The cavity 101 has an opening for docking with a motor housing 300. The power module assembly 200 is at least partially disposed within the cavity 101, and the power module assembly 200 is provided with a liquid cooling inlet 231, an internal cooling channel 232, and a liquid cooling outlet 233. The housing liquid outlet 102, the liquid cooling inlet 231, the internal cooling channel 232, the liquid cooling outlet 233, and the housing liquid inlet 103 are sequentially fluidly connected, and the docking points of the housing liquid outlet 102 and the liquid cooling inlet 231, and the docking points of the housing liquid inlet 103 and the liquid cooling outlet 233 are both provided with sealing structures.

[0025] After the power module assembly 200 is connected to the controller housing 100, the housing outlet 102 is connected to the liquid cooling inlet 231, and the housing inlet 103 is connected to the liquid cooling outlet 233. After the coolant enters the controller housing 100 from the external coolant pipeline, it enters the built-in cooling channel 232 of the power module assembly 200 through the housing outlet 102 and the liquid cooling inlet 231, and then flows back to the controller housing 100 through the liquid cooling outlet 233 and the housing inlet 103, thereby cooling the power module assembly 200. There is no need to install water pipe joints or water nozzles between the power module assembly 200 and the controller housing 100, which can shorten the coolant flow path between the power module assembly 200 and the controller housing 100, reduce flow resistance, and facilitate the cooling of the motor controller assembly. Furthermore, there are only two docking points between the power module assembly 200 and the controller housing 100, and the contact surfaces of the two docking points can be sealed with a sealing structure. The structure is simple, with few sealing points and a small sealing area.

[0026] The motor controller assembly is designed in a semi-open state, which eliminates the need for separate sealing of the housing 101. The opening of the housing 101 is directly connected to the motor housing 300 for sealing, further reducing the number of sealing points in the motor controller assembly. This eliminates the traditional upper and lower cover closed structure of the motor controller assembly, increases space utilization, and reduces the weight and cost of the motor controller assembly.

[0027] In this embodiment, the controller housing 100 has a first mating end face 104 on the outside corresponding to the housing liquid outlet 102 and the housing liquid inlet 103. The power module assembly 200 has a second mating end face on the position corresponding to the first mating end face 104. A first sealing ring 105 is provided between the first mating end face 104 and the corresponding second mating end face. In this embodiment, the first mating end face 104 has a first mounting groove surrounding the outside of the housing liquid outlet 102 or the housing liquid inlet 103. After the first mating end face 104 abuts against the corresponding second mating end face, the first sealing ring 105 is pressed into the first mounting groove.

[0028] After the power module assembly 200 is connected to the controller housing 100, the liquid outlet 102 of the housing aligns with the liquid cooling inlet 231, and the liquid inlet 103 aligns with the liquid cooling outlet 233. The first mating end face 104 and the corresponding second mating end face are in surface contact fit. Pressure is applied to the first sealing ring 105 within the first mounting groove of the first mating end face 104 by the second mating end face, pressing the rubber first sealing ring 105 tightly into the first mounting groove to ensure sealing performance. The sealing structure formed by the surface contact fit, the first mounting groove, and the first sealing ring 105 is simple and low-cost. Installation is also simple; only the first sealing ring 105 needs to be placed in the first mounting groove before connecting the power module assembly 200 to the controller housing 100.

[0029] In this embodiment, the controller housing 100 is provided with an electrically controlled liquid inlet 106 and an electrically controlled liquid outlet 107, both of which are located outside the receiving cavity 101. The electrically controlled liquid inlet 106 is used to communicate with an external coolant pipeline, and the electrically controlled liquid outlet 107 is used to communicate with the motor cooling liquid inlet 301 of the motor housing 300. The electrically controlled liquid inlet 106 and the housing outlet 102 are connected through the first internal flow channel 108 of the controller housing 100, and the housing inlet 103 and the electrically controlled liquid outlet 107 are connected through the second internal flow channel 109 of the controller housing 100.

[0030] The power module assembly 200 is connected to the controller housing 100. The housing outlet 102 is connected to the liquid cooling inlet 231, and the housing inlet 103 is connected to the liquid cooling outlet 233. The electronic control inlet 106 is connected to the external coolant pipeline. The controller housing 100 is connected to the motor housing 300, and the electronic control outlet 107 is connected to the motor cooling inlet 301 of the motor housing 300.

[0031] Coolant enters the controller housing 100's first internal flow channel 108 from an external coolant line through the electronically controlled inlet 106. It then flows through the housing outlet 102 and the liquid cooling inlet 231 into the power module assembly's internal cooling flow channel 232. Next, it flows back to the controller housing 100's second internal flow channel 109 through the liquid cooling outlet 233 and the housing inlet 103, and finally flows through the electronically controlled outlet 107 to the motor cooling inlet 301 of the motor housing 300. Both the electronically controlled inlet 106 and outlet 107 are located outside the receiving cavity 101, ensuring that the connection points between the electronically controlled inlet 106 and the external coolant line, and between the electronically controlled outlet 107 and the motor cooling inlet 301 of the motor housing 300, are outside the receiving cavity 101. This prevents coolant leakage at these connections from damaging components within the receiving cavity 101.

[0032] In this embodiment, the controller housing 100 includes a housing base plate 110 and a housing side plate 111 surrounding the outer edge of the housing base plate 110; the housing side plate 111 is provided with a pipe interface 112, the pipe interface 112 is hollow inside to form the electronically controlled liquid inlet 106; the housing side plate 111 is provided with a flange flange 113 for docking with the motor housing 300, the flange flange 113 is provided with a docking frustum 114, the docking frustum 114 is hollow inside to form the electronically controlled liquid outlet 107.

[0033] The flange 113 of the controller housing 100 is used to mate with the annular docking structure 302 on the motor housing 300. Multiple bolt holes are provided at corresponding positions on both the flange 113 and the annular docking structure 302, and the two are connected by multiple bolts. A structure is provided around the motor cooling inlet 301 to fit against the docking frustum 114. The docking frustum 114 increases the contact area at the mating point between the electronic control outlet 107 and the motor cooling inlet 301, ensuring sufficient area outside the motor cooling inlet 301 for arranging the second sealing groove and the second sealing ring 303 for end-face sealing.

[0034] In this embodiment, the power module assembly 200 includes a drive and control integrated board 210, an IGBT module 220, a liquid cooler 230, and a thin-film capacitor 240 arranged sequentially along a first direction. A current sensor 250 is disposed on the IGBT module 220. The IGBT module 220 is located on the side of the liquid cooler 230 facing the opening, and the thin-film capacitor 240 is located on the side of the liquid cooler 230 facing away from the opening. A thermal pad 260 is disposed between the side of the thin-film capacitor 240 facing away from the opening and the controller housing 100. The first direction is the direction along the opening pointing towards the bottom plate 110 of the controller housing 100. IGBT stands for Insulated Gate Bipolar Transistor. The IGBT module 220 is a commonly used composite fully controllable voltage-driven power semiconductor device in the prior art.

[0035] The thermal pad 260 is pressed and fixed between the film capacitor 240 and the controller housing 100. The film capacitor 240 transfers heat to the controller housing 100 through the thermal pad 260, and dissipates the heat to the external environment through the controller housing 100, thereby cooling the film capacitor 240.

[0036] The liquid cooling component 230 is in contact with the IGBT module 220. The IGBT module 220 transfers heat to the liquid cooling component 230, and the heat is carried away by the coolant flowing inside the liquid cooling component 230, thereby cooling the IGBT module 220.

[0037] In this embodiment, the liquid cooling inlet 231, the built-in cooling channel 232 and the liquid cooling outlet 233 are all disposed on the liquid cooling component 230. The liquid cooling component 230 is provided with a cooling contact surface 234 on the outside of the built-in cooling channel 232, and the cooling contact surface 234 is in contact with the IGBT module 220.

[0038] The cooling contact surface 234 is in contact with the IGBT module 220 to increase the heat exchange area and ensure heat dissipation.

[0039] In this embodiment, the liquid cooling component 230 is provided with a frame structure 235, and the frame structure 235 is provided with a plurality of clearance through holes. The plurality of first copper busbars 241 of the thin film capacitor 240 pass through each of the clearance through holes and are connected to the plurality of second copper busbars 221 of the IGBT module 220.

[0040] The frame structure 235 of the liquid cooling component 230 forms multiple through holes through the crisscrossing beam structure. This not only reduces its own weight, but also allows some of the through holes to serve as clearance through holes for the first copper busbar 241 to pass through. The structure in which the first copper busbar 241 passes through the clearance through holes of the frame structure 235 and connects with the second copper busbar 221 makes the structure of the power module assembly 200 more compact and improves space utilization.

[0041] In this embodiment, the liquid cooling component 230 is provided with an integrated plate connection structure 236, an IGBT connection structure 237, a capacitor connection structure 238, and a housing connection structure 239.

[0042] The IGBT connection structure 237 can be a plurality of first threaded holes located around the cooling contact surface 234 of the liquid cooler 230. The IGBT module 220 is provided with first bolt through holes at the positions corresponding to each first threaded hole. The IGBT module 220 is connected to the liquid cooler 230 by passing a bolt through the first bolt through hole of the IGBT module 220 along the first direction and threadedly connecting it to each first threaded hole.

[0043] The integrated board connection structure 236 can be a plurality of protruding first mounting posts set on the liquid cooling component 230. Each of the plurality of first mounting posts is provided with a second threaded hole. The edge of the drive and control integrated board 210 is provided with a second bolt through hole corresponding to the position of the plurality of first mounting posts. The drive and control integrated board 210 is connected to the liquid cooling component 230 by bolts passing through the second bolt through holes of the drive and control integrated board 210 along the first direction and threadedly connecting with the second threaded holes of each of the first mounting posts.

[0044] The capacitor connection structure 238 can be multiple third bolt through holes set on the liquid cooling component 230. Multiple mounting seats are respectively set at the edge of the film capacitor 240, and each mounting seat is respectively set with a third threaded hole. The film capacitor 240 is connected to the liquid cooling component 230 by bolts passing through the third bolt through holes of the liquid cooling component 230 along the first direction and threadedly connecting with the third threaded holes of each mounting seat.

[0045] The housing connection structure 239 can be multiple fourth bolt through holes set on the liquid cooling component 230. The controller housing 100 is provided with second mounting posts corresponding to the positions of each fourth bolt through hole. Each second mounting post is provided with a fourth threaded hole. The liquid cooling component 230 is connected to the controller housing 100 by bolts passing through the fourth bolt through holes of the liquid cooling component 230 in the first direction and being threadedly connected to the fourth threaded holes of each second mounting post.

[0046] During installation, firstly, connect the current sensor 250 directly to the IGBT module 220. Then, attach the thermal pad 260 to the controller housing 100 or the film capacitor 240 to achieve initial fixation of the thermal pad 260. Connect the low-voltage connector 270 to the integrated drive and control board 210. Next, install the IGBT module 220, the integrated drive and control board 210, and the film capacitor 240 to the liquid cooling component 230 to form the power module assembly 200. Finally, connect the power module assembly 200 to the controller housing 100. At this time, the thermal pad 260 is also pressed and fixed between the controller housing 100 and the film capacitor 240.

[0047] By designing a reasonable installation structure, the IGBT module 220, drive and control integrated board 210, and film capacitor 240 of the power module assembly are all integrated and mounted on the liquid cooling component 230, which simplifies the assembly of the motor controller assembly, makes the structure more compact, and further improves space utilization. At the same time, the liquid cooling component 230 has no electronic components, and using the liquid cooling component 230 as the base of the power module assembly 200 also makes the structure more stable.

[0048] In this embodiment, a low-voltage connector 270 is provided on the integrated drive and control board 210, and a through hole 115 is provided on the controller housing 100 for the low-voltage connector 270 to pass through. A sealing flange 116 is provided on the controller housing 100 at the position between the through hole 115 and the receiving cavity 101, and the sealing flange 116 protrudes from the controller housing 100. The low-voltage connector 270 needs to connect with external connectors, so the sealing flange 116 separates it from the receiving cavity 101 to prevent external dust and rainwater from entering the receiving cavity 101 through the connection between the low-voltage connector 270 and the through hole 115.

[0049] In this embodiment, the controller housing 100 is further provided with a detachable junction box cover 117. A window is provided on the side plate 111 of the controller housing 100 to communicate with the outside of the receiving cavity 101. Multiple fifth threaded holes are provided around the window. Fifth bolt through holes are provided around the detachable junction box cover 117 corresponding to the positions of each fifth threaded hole. The detachable junction box cover 117 is connected to the side plate 111 of the controller housing 100 by bolts passing through the fifth bolt through holes and connecting to the fifth threaded holes, thus closing the window of the side plate 111 of the controller housing 100.

[0050] During assembly, inspection, and after-sales maintenance, it is necessary to remove the detachable junction box cover 117 to operate the electronic components and wiring harness inside the housing cavity 101. After the assembly, inspection, and after-sales maintenance are completed, the detachable junction box cover 117 is installed to close the window of the housing side plate 111 of the controller housing 100, which can prevent dust and rainwater from entering the housing cavity 101.

[0051] like Figure 4 As shown, a motor controller assembly mounting structure in this embodiment includes a motor housing 300 and the aforementioned motor controller assembly; the motor housing 300 is provided with an annular docking structure 302, which docks with the opening of the receiving cavity 101 of the controller housing 100 to form a closed cavity for accommodating the power module assembly 200.

[0052] The annular docking structure 302 has a second sealing groove and a second sealing ring 303 outside the motor cooling inlet 301. The flange 113 of the controller housing 100 is used to dock with the annular docking structure 302 on the motor housing 300. After docking, the flange 113 presses the second sealing ring 303 into the second sealing groove, achieving end face sealing at the contact surface. Multiple bolt holes are provided at corresponding positions on the flange 113 and the annular docking structure 302, and the two are connected by multiple bolts. The annular docking structure 302 and the receiving cavity 101 of the controller housing 100 together form a closed chamber for accommodating the power module assembly 200.

[0053] One vehicle in this embodiment includes the aforementioned motor controller assembly mounting structure. The vehicle can be, but is not limited to, a pure electric vehicle (PEV / BEV), a hybrid electric vehicle (HEV), a range-extended electric vehicle (REEV), a plug-in hybrid electric vehicle (PHEV), or a new energy vehicle.

[0054] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A motor controller assembly, characterized in that, include: The controller housing (100) has an internal cavity (101) and a housing outlet (102) and a housing inlet (103) thereon. The cavity (101) has an opening for docking with the motor housing (300). And a power module assembly (200), which is at least partially disposed in the receiving cavity (101), and is provided with a liquid cooling inlet (231), an internal cooling channel (232) and a liquid cooling outlet (233). The liquid outlet (102), liquid cooling inlet (231), built-in cooling channel (232), liquid cooling outlet (233) and liquid inlet (103) of the housing are in sequential fluid communication, and the connection between the liquid outlet (102) and the liquid cooling inlet (231) of the housing and the connection between the liquid inlet (103) and the liquid cooling outlet (233) of the housing are provided with sealing structures.

2. The motor controller assembly according to claim 1, characterized in that: The controller housing (100) has a first docking end face (104) on the outside of the housing outlet (102) and the housing inlet (103). The power module assembly (200) has a second docking end face at the position corresponding to the first docking end face (104). A first sealing ring (105) is provided between the first docking end face (104) and the corresponding second docking end face.

3. The motor controller assembly according to claim 2, characterized in that: The first mating end face (104) is provided with a first mounting groove surrounding the liquid outlet (102) or liquid inlet (103) of the housing. After the first mating end face (104) abuts against the corresponding second mating end face, the first sealing ring (105) is pressed into the first mounting groove.

4. The motor controller assembly according to claim 1, characterized in that: The controller housing (100) is provided with an electrically controlled liquid inlet (106) and an electrically controlled liquid outlet (107), both of which are located outside the receiving cavity (101). The electrically controlled liquid inlet (106) is used to communicate with an external coolant pipeline, and the electrically controlled liquid outlet (107) is used to communicate with the motor cooling liquid inlet (301) of the motor housing (300). The electrically controlled liquid inlet (106) and the housing liquid outlet (102) are connected through the first built-in flow channel (108) of the controller housing (100), and the housing liquid inlet (103) and the electrically controlled liquid outlet (107) are connected through the second built-in flow channel (109) of the controller housing (100).

5. The motor controller assembly according to claim 4, characterized in that: The controller housing (100) includes a housing base plate (110) and a housing side plate (111) surrounding the outer edge of the housing base plate (110); a pipe interface (112) is provided on the housing side plate (111), the pipe interface (112) is hollow inside to form the electronic control liquid inlet (106); a flange flange (113) for docking with the motor housing (300) is provided on the housing side plate (111), a docking frustum (114) is provided on the flange flange (113), the docking frustum (114) is hollow inside to form the electronic control liquid outlet (107).

6. The motor controller assembly according to claim 1, characterized in that: The power module assembly (200) includes a drive and control integrated board (210), an IGBT module (220), a liquid cooler (230), and a thin film capacitor (240) arranged sequentially along a first direction. A current sensor (250) is provided on the IGBT module (220). The IGBT module (220) is located on the side of the liquid cooler (230) facing the opening. The thin film capacitor (240) is located on the side of the liquid cooler (230) facing away from the opening. A thermal pad (260) is provided between the side of the thin film capacitor (240) facing away from the opening and the controller housing (100). The first direction is the direction along the opening pointing towards the bottom plate (110) of the controller housing (100).

7. The motor controller assembly according to claim 6, characterized in that: The liquid cooling inlet (231), the built-in cooling channel (232), and the liquid cooling outlet (233) are all provided on the liquid cooling component (230). The liquid cooling component (230) has a cooling contact surface (234) on the outside of the built-in cooling channel (232), and the cooling contact surface (234) is in contact with the IGBT module (220). The liquid cooling component (230) is provided with a frame structure (235), and the frame structure (235) is provided with multiple clearance through holes. The multiple first copper busbars (241) of the thin film capacitor (240) pass through each of the clearance through holes and are connected to the multiple second copper busbars (221) of the IGBT module (220). The liquid cooling component (230) is provided with an integrated plate connection structure (236), an IGBT connection structure (237), a capacitor connection structure (238), and a housing connection structure (239).

8. The motor controller assembly according to claim 6, characterized in that: The drive and control integrated board (210) is provided with a low-voltage connector (270), and the controller housing (100) is provided with a through hole (115) for the low-voltage connector (270) to pass through. The controller housing (100) is provided with a sealing baffle (116) at the position between the through hole (115) and the receiving cavity (101), and the sealing baffle (116) protrudes from the controller housing (100). The controller housing (100) is also provided with a detachable junction box cover (117).

9. A motor controller assembly mounting structure, characterized in that: Includes a motor housing (300) and a motor controller assembly as described in any one of claims 1-8; the motor housing (300) is provided with an annular docking structure (302), the annular docking structure (302) docking with the opening of the receiving cavity (101) of the controller housing (100) to form a closed cavity for accommodating the power module assembly (200).

10. A vehicle, characterized in that: Includes the motor controller assembly mounting structure as described in claim 9.

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