Controller, dual-motor driving device and vehicle

Abstract

According to the controller, the dual-motor driving device and the vehicle provided by the invention, the control circuit board, the shielding plate, the power module assembly and the second driving plate are stacked, and the capacitor assembly and at least one of the power module assembly, the control circuit board, the shielding plate and the second driving plate are arranged side by side, so that the number of stacked controllers is reduced; and the height size of the controller is reduced, so that the controller is more compact in structure and smaller in size.

Description

Technical Field

[0001] This invention relates to the field of vehicle equipment, and mainly to a controller, a dual-motor drive device, and a vehicle. Background Technology

[0002] The dual-motor drive device includes a controller and two motors. The controller needs to be able to independently control the operation of the two motors. Therefore, the controller includes two power modules, two drive boards, a capacitor, a shielding board, and a control board. However, in the prior art, the arrangement structure between the power modules, drive boards, capacitors, shielding boards, and control boards is not compact enough, resulting in a large overall size of the controller. Summary of the Invention

[0003] In view of the shortcomings of the prior art, the purpose of the present invention is to provide a controller, a dual-motor drive device and a vehicle to solve the problem of the large size of existing controllers.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] A controller includes a support frame, a power module assembly, a control circuit board, a shielding plate, a second drive board, and a capacitor assembly. The power module assembly includes a first power module and a second power module, which are stacked. The control circuit board is stacked on the side of the first power module opposite to the second power module, and is electrically connected to the first power module. The shielding plate is disposed between the first power module and the control circuit board. The second drive board is stacked on the side of the second power module opposite to the first power module, and is electrically connected to both the second power module and the control board. The capacitor assembly is arranged side-by-side with at least one of the power module assembly and the second drive board, and is electrically connected to both the first and second power modules. The support frame is fixedly connected to at least one of the power module assembly, the control circuit board, the shielding plate, and the second drive board. By stacking the control circuit board, the shielding plate, the power module assembly, and the second drive board, and by arranging the capacitor assembly side-by-side with at least one of the power module assembly and the second drive board, the number of layers in the controller is reduced, the height of the controller is reduced, and thus the controller structure is more compact and smaller in size.

[0006] In some embodiments of this application, the capacitor assembly is arranged side by side with the control circuit board and the second drive board; the shielding plate is flat, and the projection of the shielding plate in the normal direction covers the capacitor assembly and the power module assembly, making the structure composed of the power module assembly, the control circuit board, the shielding plate, the second drive board and the capacitor assembly more compact.

[0007] In some embodiments of this application, the control circuit board includes a control board and a first drive board. The first drive board is electrically connected to both the control board and the first power module, and the second drive board is electrically connected to the control board. The control board and the first drive board are arranged on the same plane, and the control board and the first drive board are integrated into one unit, making the structure more compact.

[0008] In some embodiments of this application, the edge of the first drive board is directly opposite the edge of the first power module, and the edge of the control board is directly opposite the edge of the capacitor assembly. The control board is arranged in full use of the remaining positions on the plane where the first drive board is located, making the overall structure of the controller more compact, and the wiring harness leading out from the edge of the first drive board and connected to the first power module can be set to be shorter.

[0009] In some embodiments of this application, the power module assembly further includes a water-cooled plate, which is fixedly connected to the support frame and stacked between the first power module and the second power module. The first power module and the second power module are respectively disposed on two sides of the water-cooled plate. The water-cooled plate is provided with water-cooling channels for cooling the first power module and the second power module. The water-cooled plate allows for simultaneous cooling of both the first and second power modules, and the first and second power modules can be fixedly connected to the support frame via the water-cooled plate.

[0010] In some embodiments of this application, the water-cooled plate is flat and includes a first side and a second side. The first side and the second side are positioned opposite each other, and the area of ​​the first side and the second side is larger than the area of ​​the other sides of the water-cooled plate. The first power module is fixed on the first side and the second power module is fixed on the second side. This reduces the thickness of the water-cooled plate while ensuring the cooling effect on the first power module and the second power module, thereby making the controller structure more compact and smaller in size.

[0011] In some embodiments of this application, the first power module is welded to the first side, and the second power module is welded to the second side; or the water-cooling plate has a first window on the first side and a second window on the second side, both the first and second windows are connected to the water-cooling channel, the first power module is sealed to the first window, and the second power module is sealed to the second window.

[0012] In some embodiments of this application, the support frame includes a base plate located on the side of the capacitor assembly and the second drive board away from the shielding plate, and the capacitor assembly is attached to the base plate. The base plate is provided with a first cooling channel corresponding to the position of the capacitor assembly. The first cooling channel is used to cool the capacitor assembly, thereby improving the cooling effect of the controller.

[0013] In some embodiments of this application, the support frame further includes a first flow channel column and a second flow channel column. Both the first flow channel column and the second flow channel column protrude from the surface of the base plate. One end of the first flow channel column is connected to the water outlet of the first cooling channel, and the other end is connected to the water inlet of the water-cooling channel. One end of the second flow channel column is connected to the water outlet of the water-cooling channel, so that the water-cooling channel and the first cooling channel form a series channel, which facilitates the pipe connection between the water-cooling channel, the first cooling channel and the coolant supply device.

[0014] In some embodiments of this application, the second drive plate is fixed on the base plate; the base plate is provided with a second cooling channel corresponding to the position of the second drive plate, the second cooling channel is used to cool the second drive plate, and the end of the second flow channel column away from the water-cooled plate is connected to the water inlet end of the second cooling channel, thereby improving the cooling effect of the controller.

[0015] In some embodiments of this application, the controller further includes a first support column and a second support column. One end of the first support column is fixed to the base plate, and the other end is the free end of the first support column. The water-cooled plate is fixed to the free end of the first support column, and a first space is formed between the water-cooled plate and the base plate for accommodating the second drive board and the second power module. One end of the second support column is fixed to the base plate, and the other end is the free end of the second support column. The shielding plate is fixed to the free end of the second support column, and a second space is formed between the shielding plate and the base plate for mounting the second drive board, the power module assembly, and the capacitor assembly.

[0016] In some embodiments of this application, the capacitor assembly includes a capacitor and a filter. The input terminal of the filter is connected to an external three-phase power line, and the output terminal of the filter is connected to the input terminal of the capacitor. The output terminal of the capacitor faces the power module assembly. The input terminals of the first power module and the second power module face the output terminal of the capacitor and are both electrically connected to the output terminal of the capacitor.

[0017] In some embodiments of this application, the capacitor and the base plate are encapsulated as a single unit, thereby reducing the volume of the capacitor and the base plate, and thus reducing the overall volume of the controller; and / or the controller further includes a three-phase connector, which includes a first three-phase copper busbar and a second three-phase copper busbar. One end of the first three-phase copper busbar is connected to the output terminal of the first power module, and the other end is used to connect to the first motor of the dual-motor drive device. One end of the second three-phase copper busbar is connected to the output terminal of the second power module, and the other end is used to connect to the second motor of the dual-motor drive device. The first three-phase copper busbar is at least partially attached to the side of the base plate opposite to the second drive plate, and the second three-phase copper busbar is at least partially attached to the side of the base plate opposite to the second drive plate, so that the coolant inside the base plate can cool the first three-phase copper busbar and the second three-phase copper busbar.

[0018] A dual-motor drive device includes a housing, motors, a controller, and electrical connectors. The housing has a motor mounting cavity and a controller mounting cavity, and is provided with a water inlet channel and a water outlet channel. The motors include a first motor and a second motor, both mounted within the motor mounting cavity. The controller is mounted within the controller mounting cavity. The water inlet end of the first cooling channel is connected to the water inlet channel, and the water outlet end of the second cooling channel is connected to the water outlet channel. The electrical connectors include a first electrical connector and a second electrical connector. The first electrical connector is disposed between the first motor and the controller, and is electrically connected to a first power module of both the first motor and the controller. The second electrical connector is disposed between the second motor and the controller, and is electrically connected to a second power module of both the second motor and the controller.

[0019] A vehicle includes a body, wheels, and a dual-motor drive unit, wherein the dual-motor drive unit is fixed to the body, and the wheels are connected to the motors via a transmission connection.

[0020] Beneficial effects: In the controller of this application, the control circuit board, shielding plate, power module assembly and second drive board are stacked, and the capacitor assembly is arranged side by side with at least one of the power module assembly, control circuit board, shielding plate and second drive board, which reduces the number of stacked layers of the controller and reduces the height of the controller, thereby making the controller structure more compact and smaller in size.

[0021] The dual-motor drive device of this application includes a housing, a motor, an electrical connector, and the aforementioned controller. The controller is smaller in size, making it easier to arrange on the housing of the dual-motor drive device. In other words, the controller mounting cavity for mounting the controller can be made smaller, resulting in a more compact structure and smaller size for the dual-motor drive device.

[0022] The vehicle described in this application, including the aforementioned dual-motor drive unit, makes the overall structure of the vehicle more compact. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the structure of a dual-motor drive device in one embodiment.

[0024] Figure 2 yes Figure 1 An exploded view after the end caps and cover plates have been removed.

[0025] Figure 3 This is a schematic diagram of the structure of the motor control housing in one embodiment.

[0026] Figure 4 This is a schematic diagram of the controller in one embodiment.

[0027] Figure 5 yes Figure 4 The diagram shows the structure of the controller from a low-angle view.

[0028] Figure 6 yes Figure 4 The diagram shown is an exploded view of the controller after the metal cover has been removed.

[0029] Figure 7 This is a diagram showing the positional relationship between the capacitor assembly and the power module assembly.

[0030] Figure 8 This is a schematic diagram of the support structure in one embodiment, wherein the dashed lines indicate the positions of the first cooling channel and the second cooling channel.

[0031] Key component symbols: 1-Support frame; 11-Base plate; 111-First cooling channel; 12-First flow channel column; 13-Second flow channel column; 112-Second cooling channel; 14-First support column; 15-Second support column; 2-Power module assembly; 21-First power module; 23-Water-cooled plate; 3-Control circuit board; 31-Control board; 32-First drive board; 4-Shielding plate; 5-Second drive board; 6-Capacitor assembly; 61-Capacitor; 62-Filter; 63-Bus copper busbar; 7-Three-phase connector; 71-First Three-phase copper busbar; 72-Second three-phase copper busbar; 73-First connecting part; 74-Second connecting part; 75-Third connecting part; 8-Metal cover plate; 9-Connecting copper busbar; 10-Controller; 20-Housing shell; 201-Motor mounting cavity; 202-Controller mounting cavity; 203-Water inlet channel; 204-Water outlet channel; 205-Motor and electrical control housing; 206-End cover; 207-Cover plate; 30-Motor; 301-First motor; 302-Second motor; 40-Electrical connector; 401-First electrical connector; 402-Second electrical connector. Detailed Implementation

[0032] This invention provides a controller, a dual-motor drive device, and a vehicle. To make the objectives, technical solutions, and effects of this invention clearer and more explicit, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only for explaining the invention and are not intended to limit the scope of protection of the invention.

[0033] In the description of this invention, it should be understood that the terms "upper", "lower", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0034] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection, an electrical connection, or a connection that allows for communication; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0035] A vehicle includes a body, wheels, and a dual-motor drive unit, the dual-motor drive unit being fixed to the body, and the wheels being connected to the motors for transmission, so that the vehicle moves under the drive of the motors of the dual-motor drive unit.

[0036] See Figure 1-3 The dual-motor drive device includes a housing 20, a motor 30, a controller 10, and an electrical connector 40. The housing 20 has a motor mounting cavity 201 and a controller mounting cavity 202. The controller 10 is mounted in the controller mounting cavity 202. The motor 30 includes a first motor 301 and a second motor 302, both of which are mounted in the motor mounting cavity 201. The electrical connector 40 includes a first electrical connector 401 and a second electrical connector 402. The first electrical connector 401 is disposed between the first motor 301 and the controller 10 and is electrically connected to both. The second electrical connector 402 is disposed between the second motor 302 and the controller 10 and is electrically connected to both, enabling the controller 10 to control the operation of the first motor 301 and the second motor 302 respectively. The electrical connector 40 is preferably a copper busbar, but other conductive structures are also possible.

[0037] exist Figure 1 and Figure 2In the illustrated embodiment, the motor mounting cavity 201 includes a first motor mounting cavity and a second motor mounting cavity, which are coaxially arranged. The first motor 301 is mounted in the first motor mounting cavity, and the second motor 302 is mounted in the second motor mounting cavity. The controller mounting cavity 202 is located on one side of the first motor mounting cavity and the second motor mounting cavity in the circumferential direction, thereby shortening the distance between the first motor 301 and the controller 10 and between the second motor 302 and the controller 10, that is, shortening the total length of the first electrical connector 401 and the second electrical connector 402.

[0038] In one embodiment, the wheel includes a first wheel end and a second wheel end. The first wheel end is connected to a first motor 301, and the second wheel end is connected to a second motor 302, so that the first motor 301 and the second motor 302 drive the two wheel ends (i.e., the first wheel end and the second wheel end) to rotate, that is, the first wheel end and the second wheel end are driven independently by the first motor 301 and the second motor 302, forming a distributed dual-motor drive device.

[0039] In one embodiment, the wheel includes a first wheel end and a second wheel end. A first motor 301 and a second motor 302 are simultaneously connected to the first wheel end and the second wheel end for transmission. For example, the first wheel end and the second wheel end are respectively connected to the two output half shafts of the differential. The first motor 301 and the second motor 302 are both connected to the differential, so that one or both of the first motor 301 and the second motor 302 simultaneously drive the first wheel end and the second wheel end to rotate, forming a dual-motor electric drive device.

[0040] In one embodiment, the housing 20 includes a motor and electronic control housing 205, an end cap 206, and a cover plate 207. The motor mounting cavity 201 and the controller mounting cavity 202 are both disposed on the motor and electronic control housing 205. The end cap 206 is fixed to the end of the motor and electronic control housing 205 to seal the opening of the motor mounting cavity 201. The cover plate 207 is fixed to the motor and electronic control housing 205 to seal the opening of the controller mounting cavity 202.

[0041] In one embodiment, a speed reducer is also provided between the end cover 206 and the motor control housing 205. The speed reducer is connected to the output end of the motor 30, and the motor 30 is connected to the wheel end through the speed reducer.

[0042] See Figures 4-7 The controller 10 includes a support frame 1, a power module assembly 2, a control circuit board 3, a shielding plate 4, a second drive board 5, and a capacitor assembly 6. The support frame 1 is fixedly connected to the housing 20, and at least one of the power module assembly 2, the control circuit board 3, the shielding plate 4, and the second drive board 5 is fixed to the support frame 1. The power module assembly 2 includes a first power module 21 and a second power module (in...). Figure 6 and Figure 7In the illustrated embodiment, the second power module is located on the side of the water-cooled plate 23 facing away from the first power module 21, and the first power module 21 and the second power module are stacked. A control circuit board 3 is stacked on the side of the first power module 21 facing away from the second power module, and the control circuit board 3 is electrically connected to the first power module 21. A shielding plate 4 is stacked between the first power module 21 and the control circuit board 3. A second drive board 5 is stacked on the side of the second power module facing away from the first power module 21, located on the side of the shielding plate 4 facing away from the control circuit board 3, and is electrically connected to both the second power module and the control board 31. A capacitor assembly 6 is electrically connected to the first power module 21 and the second power module, and is arranged side-by-side with at least one of the power module assembly 21 and the second drive board 5.

[0043] Among them, "layered arrangement" refers to the arrangement in the vertical (Z-axis) direction, and the projections in the Z-axis direction overlap. "Side-by-side arrangement" refers to the arrangement in the horizontal (X-axis) or front-back (Y-axis) directions, and the projections in the horizontal or front-back directions overlap.

[0044] In the above, by stacking the first power module 21 and the second power module vertically, the size of the power module assembly 2 in the width direction of the controller 10 is reduced without significantly increasing the height direction. However, the height of the capacitor assembly 6 is larger than that of the second power module. By arranging the capacitor assembly 6 alongside at least one of the power module assembly 2 and the second drive board 5, this application reduces the number of stacked components and lowers the height of the controller 10 compared to the technical solution where the power module assembly 2, drive board, shielding board 4, control board, and capacitor are all stacked.

[0045] In one embodiment, the height of the capacitor assembly 6 is close to or equal to the sum of the height of the power module assembly 2 and the height of the second drive board 5. By arranging the capacitor assembly 6 side by side with the power module assembly 2 and the second drive board 5, compared to the side-by-side arrangement of the first power module 21 and the second power module, the width space of one of the power modules is utilized to set up the capacitor assembly 6, so that the side-by-side arrangement of the capacitor assembly 6 with the power module assembly 2 and the second drive board 5 does not substantially increase the width dimension of the controller 10. Here, "close to" means approximately equal. For example, if the difference between the height of the stacked power module assembly 2 and the second drive board 5 and the thickness of the capacitor assembly 6 is within ±10mm, then the height of the stacked power module assembly 2 and the second drive board 5 is close to the thickness of the capacitor assembly 6.

[0046] In this embodiment, the second drive board 5 and the control circuit board 3 are set separately, so that the height of the second drive board 5 and the power module component 2 after being stacked is close to or equal to the height of the capacitor component 6, thereby making the overall structure of the controller 10 more compact.

[0047] The control circuit board 3 includes a control board 31 and a first drive board 32. The control board 31 and the first drive board 32 are arranged on the same plane and integrated into one unit. The first drive board 32 is electrically connected to the control board 31 and the first power module 21. The second drive board 5 is electrically connected to the control board 31. High-voltage AC power flows to the first power module 21 and the second power module after being regulated by the capacitor assembly 6. The first power module 21 is electrically connected to the first motor 301 through the first electrical connector 401, and the second power module is electrically connected to the second motor 302 through the second electrical connector 402. The control circuit board 3 is electrically connected to the first power module 21 and to the second power module through the second drive board 5, so that the control circuit board 3 can control the operation of the first power module 21 and the second power module, thereby controlling the first motor 301 and the second motor 302.

[0048] The control board 31 and the first drive board 32 are integrated into one unit, making the structure of the control board 31 and the first drive board 32 more compact, reducing the space required to install the control board 31 and the first drive board 32, and further reducing the overall volume of the controller 10.

[0049] In the above-described configuration, the second drive board 5, the second power module, the first power module 21, the shielding plate 4, and the control circuit board 3 are stacked, facilitating the electrical connection between the second drive board 5 and the second power module, and between the first power module 21 and the control circuit board 3. This arrangement makes the overall structure of the controller 10 more compact and reduces its size. The shielding plate 4 is positioned between the first power module 21 and the control circuit board 3 to prevent the high-voltage current from the first power module 21 from interfering with the signal of the control circuit board 3.

[0050] When the controller 10 is installed on the housing 20, the support frame 1 is fixedly connected to the housing 20, thereby fixing the controller 10 as a whole on the housing 20. Moreover, the control circuit board 3 is set on the opening side of the controller mounting cavity 202, which facilitates the maintenance of the control board 31.

[0051] In one embodiment, the shielding plate 4 is flat, and the projection of the shielding plate 4 in the normal direction covers the capacitor assembly 6 and the power module assembly 2. The normal direction is the direction in which the control circuit board 3, the shielding plate 4, the power module assembly 2 and the second drive board 5 are stacked. That is, after the capacitor assembly 6 and the power module assembly 2 are installed, their edges are less than or equal to the edges of the shielding plate 4, and the edges of the control circuit board 3 are less than or equal to the edges of the shielding plate 4, so that the shielding plate 4 can completely shield the magnetic field of the capacitor assembly 6 and the power module assembly 2, and prevent the magnetic field of the capacitor assembly 6 and the power module assembly 2 from interfering with the control circuit board 3.

[0052] In a preferred embodiment, the edges of the plane containing the capacitor assembly 6 and the power module assembly 2, the edge of the shielding plate 4, and the edge of the control circuit board 3 are aligned, making the overall structure of the controller 10 more compact.

[0053] In a preferred embodiment, the edge of the first drive board 32 is directly opposite the edge of the first power module 21, so that when a wire harness is led out from the edge of the first drive board 32 to connect to the first power module 21, the length of the wire harness between the first drive board 32 and the first power module 21 can be shortened.

[0054] In a preferred embodiment, the edge of the control board 31 is directly opposite the edge of the capacitor assembly 6, so that the remaining space of the plane where the first drive board 32 is located can be fully utilized to arrange the control board 31, thereby making the overall structure of the controller 10 compact.

[0055] Preferably, the edges of the first drive board 32, the first power module 21, the second power module, and the second drive board 5 are all aligned. The wiring harness connecting the second drive board 5 and the control board 31 is located on the control board 31 near the first drive board 32, which shortens the length of the wiring harness between the control board 31 and the second drive board 5. Furthermore, the wiring harness connecting the control board 31 and the second drive board 5 and the wiring harness connecting the first drive board 32 and the first power module 21 can be integrated together, reducing the space required for wiring.

[0056] The power module assembly 2 also includes a water-cooled plate 23, which is fixedly connected to the support frame 1 and is located between the first power module 21 and the second power module. The first power module 21 and the second power module are respectively disposed on two sides of the water-cooled plate 23, so that the first power module 21 and the second power module are fixedly connected to the support frame 1 through the water-cooled plate 23.

[0057] The water-cooled plate 23 is equipped with water-cooling channels for cooling the first power module 21 and the second power module. When coolant flows within the water-cooling channels, the heat generated by the operation of the first power module 21 and the second power module is transferred to the coolant through the water-cooled plate 23 and carried away by the coolant from the controller 10, thus cooling the controller 10. Since the first power module 21 and the second power module are respectively located on two sides of the water-cooled plate 23, both modules can be cooled simultaneously, reducing the temperature difference between them and resulting in better cooling performance.

[0058] The water-cooled plate 23 is flat and includes a first side and a second side. The first and second sides are positioned opposite each other, and the area of ​​the first and second sides is larger than the area of ​​the other sides of the water-cooled plate 23. The first power module 21 is fixed on the first side, and the second power module is fixed on the second side. This reduces the thickness of the water-cooled plate 23 while ensuring the installation area and cooling effect of the first and second power modules, making the structure of the power module assembly 2 more compact.

[0059] In one embodiment, the first power module 21 is welded to the first side and the second power module is welded to the second side, which makes the connection between the first power module 21, the second power module and the water-cooled plate 23 convenient. Moreover, the water-cooled plate 23 does not need to be provided with additional structures for fixing the first power module 21 and the second power module, which makes the structure of the water-cooled plate 23 simple and small in size.

[0060] In one embodiment, the water-cooled plate 23 has a first opening on its first side, which communicates with a water-cooling channel. A first power module 21 is sealed and connected to the first opening, allowing the first power module 21 to contact the coolant, thereby improving the heat transfer efficiency between the first power module 21 and the coolant and enhancing the cooling effect. The first power module 21 can be fixed to the first side of the water-cooled plate 23 with screws. A sealing ring is provided on the first side at the first opening, and the first power module 21 abuts against the sealing ring to achieve a sealed connection between the first power module 21 and the first opening. Similarly, the water-cooled plate 23 has a second opening on its second side, which communicates with a water-cooling channel. A second power module is sealed and connected to the second opening, allowing the second power module to contact the coolant, thereby improving the heat transfer efficiency between the second power module and the coolant and enhancing the cooling effect. The second power module can be fixed to the second side of the water-cooled plate 23 with screws. A sealing ring is provided on the second side at the second opening, and the second power module abuts against the sealing ring to achieve a sealed connection between the second power module and the second opening.

[0061] See Figure 8The support frame 1 includes a base plate 11, a first support column 14, and a second support column 15. The base plate 11 is located on the side of the capacitor assembly 6 and the second drive plate 5 away from the shielding plate 4. The base plate 11 is fixedly connected to the outer shell 20. One end of the first support column 14 is fixed to the base plate 11, and the other end is the free end of the first support column 14. A water-cooling plate 23 is fixed to the free end of the first support column 14. A first space for accommodating the second drive plate 5 and the second power module is formed between the water-cooling plate 23 and the base plate 11. Similarly, one end of the second support column 15 is fixed to the base plate 11, and the other end is the free end of the second support column 15. The shielding plate 4 is fixed to the free end of the second support column 15. A second space for installing the second drive plate 5 and the power module assembly 2 is formed between the shielding plate 4 and the base plate 11.

[0062] The first support column 14 and the second support column 15 both protrude from the same side surface of the base plate 11. The length of the second support column 15 along the axial direction is greater than the length of the first support column 14. Therefore, the second space includes the first space.

[0063] In one embodiment, the base plate 11, the first support column 14, and the second support column 15 are integrally formed, which facilitates production and reduces costs.

[0064] In one embodiment, the support frame 1 further includes a skirt, which is connected to the base plate 11 and protrudes from the surface of the base plate 11, so that the support frame 1 forms a shell structure with at least one opening. In other embodiments, the support frame 1 may not have a skirt, which can reduce the volume of the support frame 1, facilitate the connection and wiring of the wiring harness, and thus make the overall size of the controller 10 smaller and the cost lower.

[0065] In one embodiment, a first cooling channel 111 is provided on the base plate 11 at the position corresponding to the capacitor assembly 6. The first cooling channel 111 is used to cool the capacitor assembly 6. The capacitor assembly 6 is in close contact with the base plate 11 to avoid gaps between the capacitor assembly 6 and the base plate 11, which would reduce the heat transfer efficiency of the capacitor assembly 6 to the base plate 11 and affect the cooling effect of the capacitor assembly 6.

[0066] See Figures 6-8 In one embodiment, the capacitor assembly 6 includes a capacitor 61 and a filter 62. The input terminal of the filter 62 is connected to an external three-phase power line, and the output terminal of the filter 62 is connected to the input terminal of the capacitor 61. The output terminal of the capacitor 61 faces the power module assembly 2. The input terminals of the first power module 21 and the second power module face the output terminal of the capacitor 61 and are both electrically connected to the output terminal of the capacitor 61. This reduces the electrical connection distance between the first power module 21 and the second power module and the capacitor 61, making the structure more compact.

[0067] exist Figure 7In the illustrated embodiment, capacitor 61 and filter 62 form an L-shape. The position of the first cooling channel 111 corresponds to the position of capacitor 61, meaning that the first cooling channel 111 is only used to cool capacitor 61. A busbar copper bus 63 is provided at the end of filter 62 facing away from capacitor 61, and the busbar copper bus 63 is used to connect to a high-voltage AC power supply.

[0068] In one embodiment, the capacitor 61 is encapsulated as a single unit with the base plate 11, eliminating the need for connectors and further reducing the size of the controller 10. Moreover, the capacitor 61 and the base plate 11 are fixed together by encapsulation, making the capacitor 61 and the base plate 11 fit together more closely and improving the cooling effect on the capacitor 61.

[0069] In one embodiment, the second drive board 5 is fixed on the base plate 11, and the base plate 11 is provided with a second cooling channel 112 at the position corresponding to the second drive board 5. The second cooling channel 112 is used to cool the second drive board 5 and improve the overall heat dissipation effect of the controller 10.

[0070] The support frame 1 also includes a first flow channel column 12 and a second flow channel column 13. Both the first flow channel column 12 and the second flow channel column 13 protrude from the surface of the base plate 11. One end of the first flow channel column 12 is connected to the water outlet of the first cooling channel 111, and the other end is connected to the water inlet of the water cooling channel. One end of the second flow channel column 13 is connected to the water outlet of the water cooling channel, and the end of the second flow channel column 13 away from the water cooling plate 23 is connected to the water inlet of the second cooling channel 112. This makes the first cooling channel 111, the water cooling channel and the second cooling channel 112 form a series structure, which facilitates the connection between the first cooling channel 111, the water cooling channel and the second cooling channel 112 and the water tank that provides the coolant, and simplifies the pipe connection structure.

[0071] Preferably, the second drive plate 5 is attached to the base plate 11 to improve the cooling effect on the second drive plate 5.

[0072] In one embodiment, the outer casing 20 has a water inlet channel 203 and a water outlet channel 204. The water inlet end of the first cooling channel 111 is connected to the water inlet channel 203, and the water outlet end of the second cooling channel 112 is connected to the water outlet channel 204. The water inlet end of the water inlet channel 203 is connected to the water tank, and the water outlet end of the water outlet channel 204 is connected to the water tank, so that the water tank, the water inlet channel 203, the first cooling channel 111, the water cooling channel, the second cooling channel 112, and the water outlet channel 204 are sequentially connected to form a cooling circulation channel.

[0073] The outer casing 20 has a partition between the motor mounting cavity 201 and the controller mounting cavity 202. The water inlet channel 203 and the water outlet channel 204 are set on the partition. The water inlet of the first cooling channel 111 and the water outlet of the second cooling channel 112 are both set on the side of the bottom plate 11 away from the water cooling plate 23, so that the water inlet end of the first cooling channel 111 and the water outlet end of the second cooling channel 112 can correspond to the positions of the water inlet channel 203 and the water outlet channel 204 respectively, which facilitates the connection between the water inlet end of the first cooling channel 111 and the water inlet channel 203, and the connection between the water outlet end of the second cooling channel 112 and the water outlet channel 204.

[0074] In the structure of the controller 10, high-voltage AC current flows through the capacitor assembly 6 and the power module assembly 2, which easily generates heat. By setting a first cooling channel 111 and a second cooling channel 112 on the base plate 11, and setting a water-cooled plate 23 on the power module assembly 2, the heat dissipation effect of the capacitor assembly 6 and the power module assembly 2 is improved.

[0075] In the dual-motor drive device, the first motor 301 and the second motor 302 operate at higher temperatures, meaning their operating temperatures are higher than those of the controller 10. After the controller 10 is installed on the housing 20, its base plate 11 is close to the first motor 301 and the second motor 302. By setting a first cooling channel 111 and a second cooling channel 112 on the base plate 11, the heat transferred from the first motor 301 and the second motor 302 to the controller 10 is quickly dissipated, preventing the controller 10 from overheating and burning out.

[0076] In this application, using water as the coolant is only a preferred option, but it does not limit the coolant to water; it can also be other media, such as oil.

[0077] The controller 10 also includes a three-phase connector 7, which includes a first three-phase copper busbar 71 and a second three-phase copper busbar 72. One end of the first three-phase copper busbar 71 is connected to the output end of the first power module 21, and the other end is connected to the first motor 301 of the dual-motor drive device through the first electrical connector 401. One end of the second three-phase copper busbar 72 is connected to the output end of the second power module, and the other end is connected to the second motor 302 of the dual-motor drive device through the second electrical connector 402.

[0078] The first three-phase copper busbar 71 is at least partially attached to the side of the base plate 11 opposite to the second drive plate 5, so that the coolant in the base plate 11 can cool the first three-phase copper busbar 71. Similarly, the second three-phase copper busbar 72 is at least partially attached to the side of the base plate 11 opposite to the second drive plate 5, so that the coolant in the base plate 11 can cool the second three-phase copper busbar 72.

[0079] exist Figure 6 In the embodiment shown, the first three-phase copper busbar 71 includes a first connecting segment, a second connecting segment, and a third connecting segment, which are connected in sequence. The second three-phase copper busbar 72 includes a fourth connecting segment, a fifth connecting segment, and a sixth connecting segment, which are connected in sequence.

[0080] The first connecting section and the fourth connecting section are spaced apart and fixed together by insulating material to form the first connecting part 73. The first connecting part 73 is generally flat, and its large surface is in contact with the base plate 11, increasing the contact area between the first connecting part 73 and the base plate 11 and improving the cooling effect on the first three-phase copper busbar 71 and the second three-phase copper busbar 72. The first connecting section is connected to the first electrical connector 401, and the fourth connecting section is connected to the second electrical connector 402.

[0081] The third connecting segment and the sixth connecting segment are spaced apart and fixed together by insulating material to form the third connecting part 75. The third connecting part 75 is provided corresponding to the output terminal of the first power module 21 and the output terminal of the second power module, and the third connecting segment is connected to the output terminal of the first power module 21, and the sixth connecting segment is connected to the output terminal of the second power module.

[0082] The second connecting segment and the fifth connecting segment are spaced apart and fixed together by insulating material to form the second connecting portion 74. The second connecting portion 74 is disposed between the first connecting portion 73 and the third connecting portion 75, and the second connecting segment connects the first connecting segment and the third connecting segment, while the fifth connecting segment connects the fourth connecting segment and the sixth connecting segment. The second connecting portion 74 is flat, which reduces its size in the front-rear direction of the controller 10, thereby making the structure of the controller 10 more compact.

[0083] In one embodiment, the controller 10 has a metal cover plate 8 above the second connection portion 74. The metal cover plate 8 is used to shield the magnetic field generated when the first three-phase copper busbar 71 and the second three-phase copper busbar 72 conduct electricity, so as to avoid signal interference to the operation of the control circuit board 3. In another embodiment, the metal cover plate 8 and the shielding plate 4 are configured as an integral structure.

[0084] In one embodiment, the controller 10 further includes a connecting copper busbar 9, and the output terminal of the capacitor 61 is connected to the input terminal of the first power module 21, and the output terminal of the connecting capacitor 61 is connected to the input terminal of the second power module via the connecting copper busbar 9.

[0085] In one embodiment, the controller 10 further includes a current sensor electrically connected to the drive board. The first three-phase copper busbar 71 and the second three-phase copper busbar 72 are both equipped with current sensors, which are used to detect the current on the first three-phase copper busbar 71 and the second three-phase copper busbar 72.

[0086] It is understood that those skilled in the art can make equivalent substitutions or changes to the technical solution and inventive concept of the present invention, and all such changes or substitutions should fall within the protection scope of the present invention.

Claims

1. A controller, characterized in that, include: A power module assembly includes a first power module and a second power module, wherein the first power module and the second power module are stacked. A control circuit board is stacked on the side of the first power module away from the second power module, and the control circuit board is electrically connected to the first power module; A shielding plate is stacked between the first power module and the control circuit board; The second drive board is stacked on the side of the second power module away from the first power module, and the second drive board is electrically connected to both the second power module and the control circuit board. A capacitor assembly is arranged side-by-side with at least one of the power module assembly and the second driver board, and is electrically connected to the first power module and the second power module; The support frame is fixedly connected to at least one of the power module assembly, the control circuit board, the shielding plate, and the second drive board.

2. The controller according to claim 1, characterized in that, The capacitor assembly is arranged side by side with the power module assembly and the second driver board; The shielding plate is flat, and its projection in the normal direction covers the capacitor assembly and the power module assembly.

3. The controller according to claim 2, characterized in that, The control circuit board includes a control board and a first drive board. The first drive board is electrically connected to both the control board and the first power module, and the second drive board is electrically connected to the control board. The control board and the first drive board are arranged on the same plane, and the control board and the first drive board are integrated into one unit.

4. The controller according to claim 2, characterized in that, The position of the first driver board is directly opposite the position of the first power module, and the position of the control board is directly opposite the position of the capacitor assembly.

5. The controller according to any one of claims 1-4, characterized in that, The power module assembly also includes a water-cooled plate, which is fixedly connected to the support frame and is stacked between the first power module and the second power module. The first power module and the second power module are respectively disposed on two sides of the water-cooled plate. The water-cooled plate is provided with water-cooling channels, which are used to cool the first power module and the second power module.

6. The controller according to claim 5, characterized in that, The water-cooled plate is flat and includes a first side and a second side. The first side and the second side are positioned opposite each other, and the area of ​​the first side and the second side is larger than the area of ​​the other sides of the water-cooled plate. The first power module is fixed on the first side, and the second power module is fixed on the second side.

7. The controller according to claim 6, characterized in that, The first power module is welded to the first side, and the second power module is welded to the second side; or The water-cooled plate has a first window on the first side and a second window on the second side. Both the first window and the second window are connected to the water-cooling channel. The first power module is sealed and connected to the first window, and the second power module is sealed and connected to the second window.

8. The controller according to claim 5, characterized in that, The support frame includes a base plate located on the side of the capacitor assembly and the second drive plate away from the shielding plate, and the capacitor assembly is attached to the base plate. The base plate is provided with a first cooling channel corresponding to the position of the capacitor assembly, and the first cooling channel is used to cool the capacitor assembly.

9. The controller according to claim 8, characterized in that, The support frame also includes a first flow channel column and a second flow channel column. Both the first flow channel column and the second flow channel column protrude from the surface of the base plate. One end of the first flow channel column is connected to the water outlet of the first cooling channel, and the other end is connected to the water inlet of the water cooling channel. One end of the second flow channel column is connected to the water outlet of the water cooling channel.

10. The controller according to claim 9, characterized in that, The second drive plate is fixed on the base plate; The base plate is provided with a second cooling channel at the position corresponding to the second drive plate. The second cooling channel is used to cool the second drive plate. The end of the second flow channel column away from the water-cooled plate is connected to the water inlet end of the second cooling channel.

11. The controller according to claim 8, characterized in that, The controller further includes a first support column and a second support column. One end of the first support column is fixed to the base plate, and the other end is the free end of the first support column. The water-cooled plate is fixed to the free end of the first support column. A first space for accommodating the second drive board and the second power module is formed between the water-cooled plate and the base plate. One end of the second support column is fixed to the base plate, and the other end is the free end of the second support column. The shielding plate is fixed to the free end of the second support column. A second space for installing the second drive board, the power module assembly, and the capacitor assembly is formed between the shielding plate and the base plate.

12. The controller according to claim 8, characterized in that, The capacitor assembly includes a capacitor and a filter. The input terminal of the filter is connected to an external three-phase power line, and the output terminal of the filter is connected to the input terminal of the capacitor. The output terminal of the capacitor faces the power module assembly. The input terminals of the first power module and the second power module face the output terminal of the capacitor and are both electrically connected to the output terminal of the capacitor.

13. The controller according to claim 12, characterized in that, The capacitor is encapsulated integrally with the base plate; and / or The controller further includes a three-phase connector comprising a first three-phase copper busbar and a second three-phase copper busbar. One end of the first three-phase copper busbar is connected to the output terminal of the first power module, and the other end is used to connect to the first motor of the dual-motor drive device. One end of the second three-phase copper busbar is connected to the output terminal of the second power module, and the other end is used to connect to the second motor of the dual-motor drive device. At least a portion of the first three-phase copper busbar is attached to the side of the base plate opposite to the second drive plate, and at least a portion of the second three-phase copper busbar is attached to the side of the base plate opposite to the second drive plate.

14. A dual-motor drive device, characterized in that, include: The outer casing has a motor mounting cavity and a controller mounting cavity, and the outer casing is provided with a water inlet channel and a water outlet channel; The motor includes a first motor and a second motor, both of which are installed inside the motor mounting cavity. The controller as described in any one of claims 10-13 is installed in the controller mounting cavity, wherein the water inlet end of the first cooling channel is connected to the water inlet channel, and the water outlet end of the second cooling channel is connected to the water outlet channel; An electrical connector includes a first electrical connector and a second electrical connector. The first electrical connector is disposed between the first motor and the controller and is electrically connected to a first power module of the first motor and the controller. The second electrical connector is disposed between the second motor and the controller and is electrically connected to a second power module of the second motor and the controller.

15. A vehicle, characterized in that, It includes a vehicle body, wheels, and a dual-motor drive device as described in claim 14, wherein the dual-motor drive device is fixed to the vehicle body, and the wheels are connected to the motors via a transmission connection.

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