Direct-current busbar filtering assembly, inverter assembly and vehicle

Abstract

The invention discloses a direct-current busbar filtering assembly, an inverter assembly and a vehicle, and belongs to the technical field of vehicles, the direct-current busbar filtering assembly comprises an insulating shell, a high-voltage connector, a magnetic ring, a grounding piece, a plurality of Y capacitors and two busbars, the insulating shell is provided with a central through hole, a first mounting groove and a second mounting groove, the first mounting groove is wound around the outer side of the central through hole, the second mounting groove is located in the side, away from the central through hole, of the first mounting groove, the high-voltage connector penetrates through the central through hole, the magnetic ring is mounted in the first mounting groove, the grounding piece is mounted on the insulating shell, and each Y capacitor is mounted in the second mounting groove. The high-voltage connector, the magnetic ring, the grounding piece, the Y capacitors and the two busbars can be integrated and fixed on the insulating shell, the direct-current busbar filtering assembly is compact in structure and small in occupied space, meanwhile, the magnetic ring and the Y capacitors can form an efficient common-mode filter, direct current entering an inverter is filtered from the source, and good electromagnetic compatibility is achieved.

Description

Technical Field

[0001] This invention relates to the field of vehicle technology, and more specifically, to a DC bus filter assembly, an inverter assembly, and a vehicle. Background Technology

[0002] With the continuous upgrading and maturation of new energy vehicle and intelligent connected vehicle technologies, the requirements for electromagnetic compatibility (EMC) performance of vehicles are becoming increasingly stringent. As the power source of new energy vehicles, the power battery and the inverter, as the energy conversion device, are responsible for converting the DC power from the power battery into AC power to be input to the drive motor. The DC bus is the bridge connecting the battery and the inverter. In order to meet the electromagnetic compatibility requirements of vehicles, it is necessary to filter and block interference signals flowing through the inverter.

[0003] In related technologies, the filters in inverters are usually arranged independently in the middle of the inverter. They occupy a lot of space, have high manufacturing and assembly costs, and the current still generates a lot of electromagnetic interference before flowing through the filter, resulting in poor electromagnetic compatibility. Summary of the Invention

[0004] The present invention aims to at least partially solve one of the aforementioned technical problems in the prior art. To this end, the present invention proposes a DC busbar filter assembly with better electromagnetic compatibility.

[0005] The present invention also proposes an inverter assembly having the above-mentioned DC bus filter component.

[0006] The present invention also proposes a vehicle having the above-described inverter assembly.

[0007] According to an embodiment of the present invention, a DC busbar filter assembly includes: an insulating housing having a central through hole, a first mounting groove and a second mounting groove, the first mounting groove being disposed around the outside of the central through hole, and the second mounting groove being located on the side of the first mounting groove away from the central through hole; a high-voltage connector passing through the central through hole; a magnetic ring mounted in the first mounting groove; a grounding element mounted in the insulating housing; a plurality of Y capacitors, each of the Y capacitors being mounted in the second mounting groove; and two busbars, each of the busbars having an input terminal, an output terminal and a grounding terminal, the input terminal being electrically connected to the high-voltage connector, the output terminal being located outside the insulating housing, and the grounding terminal being electrically connected to the grounding element through at least one of the Y capacitors.

[0008] According to an embodiment of the present invention, the DC busbar filter assembly can integrate and fix a high-voltage connector, a magnetic ring, a grounding component, multiple Y capacitors, and two busbars in the insulating housing. The DC busbar filter assembly has a compact structure and occupies little space. At the same time, the magnetic ring and multiple Y capacitors can form a high-efficiency common-mode filter to filter the DC power entering the inverter from the source, and has good electromagnetic compatibility.

[0009] According to some embodiments of the present invention, a portion of the busbar is embedded within the integrally injection-molded insulating housing.

[0010] According to some embodiments of the present invention, at least one mounting hole is provided on the insulating housing, the mounting hole being adapted to be connected to the inverter housing by a corresponding first fastener, and the output terminal being located inside the inverter housing.

[0011] According to some embodiments of the present invention, the first fastener includes: a first bushing and a first bolt, the first bushing being fitted into the mounting hole, and the first bolt passing through the first bushing and adapted to be connected to the housing of the inverter.

[0012] According to some embodiments of the present invention, the grounding member is electrically connected to the housing of the inverter via the first fastener.

[0013] According to some embodiments of the present invention, the insulating housing has at least one locating pin adapted to engage with the housing of the inverter.

[0014] According to some embodiments of the present invention, the input terminal is detachably connected to the high-voltage connector via a second fastener.

[0015] According to some embodiments of the present invention, the first mounting groove is filled with a first sealant covering the magnetic ring, and the second mounting groove is filled with a second sealant covering the Y capacitor.

[0016] An inverter assembly according to another embodiment of the present invention includes the DC bus filter component described above.

[0017] A vehicle according to another embodiment of the present invention includes the inverter assembly described above.

[0018] The inverter assembly and vehicle have the same advantages over the prior art as the aforementioned DC bus filter assembly, and will not be repeated here.

[0019] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0020] Figure 1This is a schematic diagram of a DC busbar filter assembly according to an embodiment of the present invention; Figure 2 This is an exploded view of a DC busbar filter assembly according to an embodiment of the present invention; Figure 3 This is a bottom view of a DC busbar filter assembly according to an embodiment of the present invention; Figure 4 This is a schematic diagram of the structure of the DC busbar filter assembly at the grounding member and the first fastener according to an embodiment of the present invention.

[0021] Figure label: Insulating housing 1; central through hole 11; first mounting groove 12; second mounting groove 13; mounting hole 14; positioning pin 15; support surface 16; 2. High-voltage connector; 3. Magnetic ring; 4. Grounding component; 5. Y capacitor; Busbar 6; Input terminal 61, Output terminal 62; Ground terminal 63; First fastener 7; First bushing 71; First bolt 72; DC busbar filter assembly 10. Detailed Implementation

[0022] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0023] In the description of this invention, it should be understood that the terms "inner" and "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and 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, and therefore should not be construed as a limitation of this invention.

[0024] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0025] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; 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.

[0026] The DC busbar filter assembly 10, the inverter assembly, and the vehicle according to embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0027] Reference Figures 1-3 As shown, the DC busbar filter assembly 10 according to an embodiment of the present invention includes: an insulating housing 1, a high-voltage connector 2, a magnetic ring 3, a grounding component 4, a plurality of Y capacitors 5, and two busbars 6. The insulating housing 1 has a central through hole 11, a first mounting groove 12, and a second mounting groove 13. The first mounting groove 12 is disposed around the outside of the central through hole 11, and the second mounting groove 13 is located on the side of the first mounting groove 12 away from the central through hole 11. The high-voltage connector 2 passes through the central through hole 11. The magnetic ring 3 is mounted in the first mounting groove 12. The grounding component 4 is mounted in the insulating housing 1. Each Y capacitor 5 is mounted in the second mounting groove 13. Each busbar 6 has an input terminal 61, an output terminal 62, and a grounding terminal 63. The input terminal 61 is electrically connected to the high-voltage connector 2. The output terminal 62 is located on the outside of the insulating housing 1. The grounding terminal 63 is electrically connected to the grounding component 4 through at least one Y capacitor 5.

[0028] It should be noted that the DC bus filter assembly 10 can be used in the vehicle's inverter. The vehicle's battery pack can be electrically connected to the power components in the inverter through the DC bus filter assembly 10. The inverter can convert the DC power output from the battery into AC power and output it to the drive motor. The DC bus filter assembly 10 can be integrated with the inverter.

[0029] The high-voltage connector 2 of the DC busbar filter assembly 10 is suitable for electrical connection with the battery pack, and the output terminal 62 of the busbar 6 is suitable for electrical connection with the power components inside the inverter. That is, the DC power output from the battery pack is connected to the power components inside the inverter through the high-voltage connector 2 and the two busbars 6 in sequence. The two busbars 6 correspond to the positive and negative terminals of the DC power, respectively. Since the magnetic ring 3 is sleeved on the outside of the high-voltage connector 2, the magnetic ring 3 can perform primary filtering on the current flowing through the high-voltage connector 2. Each busbar 6 is electrically connected to the ground terminal 63 through at least one corresponding capacitor, which plays a role in suppressing common-mode interference and protecting the stability and safety of the power supply circuit, i.e., secondary filtering, to solve the problem of electromagnetic interference. At the same time, the DC busbar filter assembly 10 can filter the DC power entering the inverter from the source, which can achieve a better filtering effect.

[0030] The insulating housing 1 can support and fix the components inside it, and has good electrical insulation performance to ensure the safety of the DC bus filter assembly 10. The insulating housing 1 has a central through hole 11, a first mounting groove 12 and a second mounting groove 13. The high-voltage connector 2 can be fixed inside the central through hole 11. The first mounting groove 12 is arranged around the outside of the central through hole 11 and is used to fix the magnetic ring 3 so that the magnetic ring 3 can be sleeved on the outside of the high-voltage connector 2 to achieve the filtering function. The magnetic ring 3 can block the propagation of high-frequency common-mode current through high inductance, while allowing useful power current to pass.

[0031] Grounding component 4 is installed on insulating housing 1. Grounding component 4 can be directly or indirectly connected to the vehicle body and grounded. Second mounting slot 13 is located outside of first mounting slot 12. Each Y capacitor 5 is installed in second mounting slot 13. Second mounting slot 13 can fix and protect Y capacitor 5. Each busbar 6 has an input terminal 61, an output terminal 62 and a grounding terminal 63. Input terminal 61 is electrically connected to high voltage connector 2. Output terminal 62 is located outside insulating housing 1 and is suitable for electrical connection to power components in inverter. Grounding terminal 63 is electrically connected to grounding component 4 through one Y capacitor 5 or a group of Y capacitors composed of multiple Y capacitors 5. Y capacitor 5 can provide a low impedance return path for common mode noise and filter out common mode interference.

[0032] According to an embodiment of the present invention, the DC busbar filter assembly 10 has an insulating housing 1 that can integrate and fix a high-voltage connector 2, a magnetic ring 3, a grounding component 4, multiple Y capacitors 5 and two busbars 6. The DC busbar filter assembly 10 has a compact structure and occupies little space. At the same time, the magnetic ring 3 and multiple Y capacitors 5 can form a high-efficiency common-mode filter to filter the DC power entering the inverter from the source, and has good electromagnetic compatibility.

[0033] In some embodiments of the present invention, a portion of the busbar 6 is embedded within an integrally injection-molded insulating housing 1.

[0034] Specifically, a portion of the busbar 6 is embedded within the insulating housing 1 to enhance the connection strength between the busbar 6 and the insulating housing 1. The insulating housing 1 can also protect and structurally reinforce the busbar 6, reducing the risk of deformation. The insulating housing 1 can be an integrally injection-molded part. During the injection molding of the insulating housing 1, the busbar 6 can be placed as an insert within the mold of the insulating housing 1. After the insulating housing 1 is injection-molded, the busbar 6 and the insulating housing 1 are connected as one unit to facilitate the assembly of the busbar 6 and the insulating housing 1.

[0035] It should be noted that the material of the insulating shell 1 can be an engineering plastic with certain strength, rigidity, heat resistance and dimensional stability, such as PA9T-GF35, which is a composite material obtained by adding 35% glass fiber to the base resin PA9T for reinforcement modification.

[0036] In some embodiments of the present invention, reference is made to... Figure 1 , Figure 2 and Figure 4 As shown, the insulating housing 1 has at least one mounting hole 14, which is adapted to be connected to the inverter housing by a corresponding first fastener 7, and the output terminal 62 is located inside the inverter housing.

[0037] Specifically, the first fastener 7 can be inserted through the mounting hole 14 and connected to the inverter housing. The insulating housing 1 is installed on the inverter housing through the first fastener 7. At the same time, the output terminals 62 of the two busbars 6 can be located inside the inverter housing so that the output terminals 62 can be connected to the power components inside the inverter.

[0038] Since the output terminal 62 is located inside the inverter housing, that is, the inverter housing has an opening that allows the output terminal 62 to enter, the insulating housing 1 can be installed at the opening to seal the opening. The insulating housing 1 and the inverter housing together define a mounting cavity for accommodating electrical components, which has a high degree of integration.

[0039] In some embodiments of the present invention, reference is made to... Figures 1-4 As shown, the first fastener 7 includes a first bushing 71 and a first bolt 72. The first bushing 71 is fitted into the mounting hole 14, and the first bolt 72 passes through the first bushing 71 and is adapted to be connected to the housing of the inverter.

[0040] Specifically, the first bushing 71 can be integrally formed with the injection-molded insulating housing 1 by means of an insert. The strength of the first bushing 71 is greater than that of the insulating housing 1. The first bushing 71 can be a steel structural component plated with color zinc (the grade can be 1215MS). Color zinc plating can improve the corrosion resistance and service life of the first bushing 71. When the first bolt 72 passes through the first bushing 71 and is connected to the housing of the inverter, the head of the first bolt 72 can abut against the axial surface of the first bushing 71. The first bushing 71 can support and limit the head of the first bolt 72 and evenly distribute the load to the insulating housing 1 to reduce the risk of damage to the insulating housing 1.

[0041] In other embodiments of the present invention (not shown in the figures), the first fastener 7 may also be a fastening connection structure such as a rivet or a buckle.

[0042] In some embodiments of the present invention, reference is made to... Figure 1 , Figure 2 and Figure 4 As shown, the grounding component 4 is electrically connected to the inverter housing through the first fastener 7, and the inverter housing is grounded through the vehicle body.

[0043] Specifically, the grounding component 4 can be a grounding ring copper busbar structure. The grounding component 4 can abut against the first bushing 71. The first bolt 72 passes through the grounding component 4 and presses it against the first bushing 71. The grounding component 4 can be grounded by the first fastener 7 connected to the inverter housing, so as to realize the reuse of the function of the first fastener 7 and reduce the difficulty and cost of grounding the grounding component 4.

[0044] Among them, the grounding component 4 has two connecting arms, and the two connecting arms correspond one-to-one with the grounding terminals 63 of the two busbars 6. The connecting arms and the corresponding grounding terminals 63 are connected through multiple parallel Y capacitors 5.

[0045] In some embodiments of the present invention, reference is made to... Figure 1 and Figure 2 As shown, the insulating housing 1 has at least one positioning pin 15, which is adapted to be positioned and engaged with the inverter housing. The positioning pin 15 can be used for positioning when the insulating housing 1 is assembled with the inverter housing, so as to facilitate the assembly of the insulating housing 1 and the inverter housing and ensure the assembly accuracy.

[0046] In some embodiments of the present invention, reference is made to... Figure 1 and Figure 2As shown, the number of positioning pins 15 can be the same as the number of mounting holes 14 and their positions can be adjacent. For example, there are two mounting holes 14 located on both sides outside the first mounting groove 12. There are also two positioning pins 15, each of which is adjacent to the corresponding mounting hole 14. During assembly, the positioning pins 15 are positioned and engaged with the inverter housing, which can improve the positional accuracy of the mounting holes 14 and the first fastener 7, so as to facilitate the assembly of the insulating housing 1 and the inverter housing.

[0047] In some embodiments of the present invention, reference is made to... Figure 1 and Figure 2 As shown, the insulating housing 1 also has a support surface 16, and the positioning pin 15 and the mounting hole 14 can both be provided on the support surface 16. The support surface 16 is adapted to abut against and connect with the housing of the inverter.

[0048] In some embodiments of the present invention, reference is made to... Figure 3 As shown, input terminal 61 is detachably connected to high-voltage connector 2 via a second fastener, wherein... Figure 3 The second fastener is not shown. The input end 61 of the busbar 6 may have a connection hole. The second fastener can pass through the connection hole and be connected to the high-voltage connector 2. The second fastener can be a screw or a rivet. The second fastener is removable to facilitate the assembly, maintenance and replacement of the high-voltage connector 2.

[0049] In some embodiments of the present invention, the first mounting groove 12 is filled with a first sealant covering the magnetic ring 3. That is, after the magnetic ring 3 is installed in the first mounting groove 12, the first mounting groove 12 is filled with sealant to form a first sealant covering the magnetic ring 3. The first sealant can improve the connection strength between the magnetic ring 3 and the first mounting groove 12, and can also protect the magnetic ring 3, thereby improving the reliability and service life of the magnetic ring 3.

[0050] The second mounting groove 13 is filled with a second sealant covering the Y capacitor 5. That is, after the Y capacitor 5 is installed in the second mounting groove 13, the second mounting groove 13 is filled with sealant to form a second sealant covering the Y capacitor 5. The second sealant can improve the connection strength between the Y capacitor 5 and the second mounting groove 13, and can also protect the Y capacitor 5, improve the reliability and service life of the magnetic ring 3.

[0051] Meanwhile, since the magnetic ring 3 and the Y capacitor 5 are encapsulated in the first mounting groove 12 and the second mounting groove 13 of the insulating housing 1, the busbar 6 and the filter are tightly integrated. Compared with setting an independent filter in the inverter, the integrated structure of this embodiment of the invention has a positive effect of reducing processes and reducing costs for large-scale production. For the inverter housing layout, it reduces the space occupied and improves the space utilization rate.

[0052] According to an embodiment of the present invention, the DC busbar filter assembly 10, the high-voltage connector 2, and the two busbars 6 can achieve a 90-degree current transmission function. The busbars 6 are embedded parallel to the insulating housing 1 through a stamping process. The output end 62 of the busbar 6 is suitable for welding and connecting to the large capacitor of the inverter. The input end 61 of the busbar 6 is bolted to the high-voltage connector 2. The extension direction of the high-voltage connector 2 is parallel to the thickness direction of the busbar 6. The insulating housing 1 can be positioned on the inverter housing by two positioning pins 15. The insulating housing 1 and the inverter housing are connected by bolts and bushings. The high-voltage connector 2 is inserted through the magnetic ring 3 to perform initial filtering of the current flowing through the high-voltage connector 2. In addition, under the action of the grounding component 4, the Y capacitor group and the positive and negative busbars 6 are connected respectively, which plays a role in suppressing common-mode interference and protecting the stability and safety of the power supply circuit.

[0053] The DC busbar filter assembly 10 integrates a filter consisting of a magnetic ring 3 and a Y capacitor 5, as well as a busbar 6. Compared to a separate structure, it saves space, and from the perspective of filtering effect, it filters the DC power entering the inverter at the source, achieving a better filtering effect. In addition, the integrated DC busbar filter assembly 10 eliminates the need for electrical components connected to the filter and the supporting housing compared to a stand-alone DC busbar, thus saving costs.

[0054] An inverter assembly according to another embodiment of the present invention includes the DC bus filter component 10 of the above embodiment.

[0055] Specifically, the inverter assembly may include an inverter and a DC bus filter assembly 10. The insulating housing 1 is connected to the inverter housing, the bus 6 is electrically connected to the inverter, and the vehicle's battery pack can be electrically connected to the inverter through the DC bus filter assembly 10. The inverter can convert the DC power output from the battery into AC power and output it to the drive motor.

[0056] According to an embodiment of the present invention, the inverter assembly of the DC bus filter component 10 has an insulating housing 1 that can integrate and fix a high voltage connector 2, a magnetic ring 3, a grounding component 4, multiple Y capacitors 5 and two busbars 6. The DC bus filter component 10 has a compact structure and occupies little space. At the same time, the magnetic ring 3 and multiple Y capacitors 5 can form a high-efficiency common-mode filter to filter the DC power entering the inverter from the source, and has good electromagnetic compatibility.

[0057] A vehicle according to another embodiment of the present invention includes the inverter assembly of the above embodiments.

[0058] According to an embodiment of the present invention, the insulating housing 1 of the DC bus filter assembly 10 can integrate and fix a high-voltage connector 2, a magnetic ring 3, a grounding component 4, multiple Y capacitors 5 and two busbars 6. The DC bus filter assembly 10 has a compact structure and occupies little space. At the same time, the magnetic ring 3 and multiple Y capacitors 5 can form a high-efficiency common-mode filter to filter the DC power entering the inverter from the source, and has good electromagnetic compatibility.

[0059] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. In addition, those skilled in the art can combine and integrate the different embodiments or examples described in this specification.

[0060] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A DC busbar filter assembly, characterized in that, include: An insulating housing (1) has a central through hole (11), a first mounting groove (12) and a second mounting groove (13). The first mounting groove (12) is disposed around the outside of the central through hole (11), and the second mounting groove (13) is located on the side of the first mounting groove (12) away from the central through hole (11). A high-voltage connector (2) is provided through the central through hole (11); A magnetic ring (3) is installed in the first mounting groove (12); Grounding component (4), said grounding component (4) is installed on the insulating housing (1); Multiple Y capacitors (5), each of which is mounted in the second mounting slot (13); Two busbars (6), each of the busbars (6) having an input terminal (61), an output terminal (62) and a ground terminal (63), the input terminal (61) being electrically connected to the high-voltage connector (2), the output terminal (62) being located outside the insulating housing (1), and the ground terminal (63) being electrically connected to the grounding member (4) through at least one of the Y capacitors (5).

2. The DC busbar filter assembly according to claim 1, characterized in that, A portion of the busbar (6) is embedded within the integrally injection-molded insulating housing (1).

3. The DC busbar filter assembly according to claim 1 or 2, characterized in that, The insulating housing (1) has at least one mounting hole (14) which is adapted to be connected to the inverter housing by a corresponding first fastener (7), and the output terminal (62) is located inside the inverter housing.

4. The DC busbar filter assembly according to claim 3, characterized in that, The first fastener (7) includes a first bushing (71) and a first bolt (72), wherein the first bushing (71) is fitted into the mounting hole (14), and the first bolt (72) passes through the first bushing (71) and is adapted to be connected to the housing of the inverter.

5. The DC busbar filter assembly according to claim 3, characterized in that, The grounding component (4) is electrically connected to the inverter housing via the first fastener (7).

6. The DC busbar filter assembly according to claim 3, characterized in that, The insulating housing (1) has at least one locating pin (15) adapted to engage with the housing of the inverter.

7. The DC busbar filter assembly according to claim 1, characterized in that, The input terminal (61) is detachably connected to the high-voltage connector (2) via a second fastener.

8. The DC busbar filter assembly according to claim 1, characterized in that, The first mounting groove (12) is filled with a first sealant covering the magnetic ring (3), and the second mounting groove (13) is filled with a second sealant covering the Y capacitor (5).

9. An inverter assembly, characterized in that, Includes the DC bus filter assembly according to any one of claims 1-8.

10. A vehicle, characterized in that, Including the inverter assembly according to claim 9.

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