Integrated controller and control method thereof, integrated control system, control device and electric vehicle

Abstract

The invention discloses an integrated controller and a control method thereof, an integrated control system, a control device and an electric automobile, and relates to the technical field of electric automobiles, the integrated controller comprises an alternating current input end, a direct current input end, and a three-phase bridge arm circuit, a PFC switch circuit and a voltage conversion circuit which are sequentially connected in series between the alternating current input end and the direct current input end, and a mode switching circuit. The direct current input end is used for accessing an energy storage module; the alternating current input end is used for accessing alternating current; one end of the mode switching circuit is connected with the input end of the PFC switching circuit, and the other end of the mode switching circuit is connected with the direct current input end; in the charging mode, the mode switching circuit is used for disconnecting the electrical connection between the PFC switching circuit and the direct current input end; in the operation mode, the mode switching circuit is used for conducting electric connection between the PFC switching circuit and the direct current input end so as to bypass the voltage conversion circuit. The invention aims to improve the integration level of the integrated controller and reduce the circuit design complexity and research and development cost.

Description

Technical Field

[0001] This invention relates to the field of electric vehicle technology, and in particular to an integrated controller and its control method, an integrated control system, a control device, and an electric vehicle. Background Technology

[0002] Currently, the integration of integrated controllers on the market mainly focuses on the integration of high-voltage components in the power domain, with physical integration and semi-deep integration as the primary integration directions. This typically involves integrating multiple functional boards into a single mechanical housing, sharing the housing, wiring harnesses, cooling systems, or some components sharing control circuitry, thereby achieving a compact and unified structure. Even in the area of ​​power topology integration, only the reuse of power topologies between the DC / DC converter and the OBC is achieved, but the integration and reuse of power topologies remains limited, and the integration effect is not significant. Summary of the Invention

[0003] The main objective of this invention is to propose an integrated controller and its control method, an integrated control system, a control device, and an electric vehicle, aiming to improve the integration level of the integrated controller and reduce the complexity of circuit design and R&D costs.

[0004] To achieve the above objectives, the present invention proposes an integrated controller, comprising:

[0005] AC input terminal, used for connecting to AC power;

[0006] DC input terminal, used to connect to energy storage module;

[0007] The three-phase bridge arm circuit, the PFC switch circuit, and the voltage conversion circuit are connected in series between the AC input terminal and the DC input terminal.

[0008] A mode switching circuit, one end of which is connected to the input terminal of the PFC switch circuit, and the other end of which is connected to the DC input terminal;

[0009] The integrated controller has a charging mode and an operating mode. In the charging mode, the mode switching circuit is used to disconnect the electrical connection between the PFC switching circuit and the DC input terminal.

[0010] In operation mode, the mode switching circuit is used to connect the PFC switching circuit to the DC input terminal to bypass the voltage conversion circuit.

[0011] In one embodiment, the integrated controller further includes a motor module, a first terminal of which is electrically connected to the AC input terminal, and a second terminal of which is electrically connected to the three-phase bridge arm circuit;

[0012] In charging mode, the motor module operates in an inductor state to store / release energy; in operating mode, the motor module operates in a winding state to generate a rotating magnetic field when AC power is connected to the AC input terminal.

[0013] In one embodiment, the integrated controller further includes a capacitor connected in series between the PFC switching circuit and the voltage conversion circuit;

[0014] In charging mode, the capacitor operates in power factor correction mode; in operating mode, the capacitor operates in DC bus capacitor mode.

[0015] In one embodiment, in charging mode, the three-phase bridge arm circuit and the PFC switch circuit operate in rectification mode to rectify the AC power connected to the AC input terminal and output DC voltage to the voltage conversion circuit, so that the voltage conversion circuit converts the received DC voltage and outputs it.

[0016] In operation mode, the three-phase bridge arm circuit and the PFC switch circuit operate in inverter mode, which is used to invert the DC voltage connected to the DC input terminal and output AC voltage.

[0017] In one embodiment, the PFC switching circuit includes an upper bridge switch and a lower bridge switch, the motor module includes a three-phase winding, and the three-phase bridge arm circuit includes a first bridge arm circuit, a second bridge arm circuit, and a third bridge arm circuit; the midpoint of the first bridge arm circuit, the midpoint of the second bridge arm circuit, and the midpoint of the third bridge arm circuit are respectively connected to the three-phase winding.

[0018] In charging mode, the upper and lower bridge arm switches of any one of the first bridge arm circuit, the second bridge arm circuit, and the third bridge arm circuit are turned on / off at a first preset frequency to form a circuit with the motor module, so that the motor module stores / releases energy.

[0019] In operation mode, the upper and lower bridge arm switches in the first, second, and third bridge arm circuits are turned on / off at a second preset frequency.

[0020] In one embodiment, the integrated controller further includes:

[0021] The main controller is electrically connected to the controlled terminal of the three-phase bridge arm circuit, the controlled terminal of the PFC switch circuit, and the controlled terminal of the voltage conversion circuit.

[0022] In charging mode, the main controller is used to control the three-phase bridge arm circuit and the PFC switch circuit to operate in rectification mode, so as to rectify the AC power connected to the AC input terminal and output DC voltage to the voltage conversion circuit, and control the voltage conversion circuit to convert the received DC voltage and output it.

[0023] In operation mode, the main controller is used to control the three-phase bridge arm circuit and the PFC switch circuit to operate in inverter mode, so as to output AC voltage after inverting the DC voltage connected to the DC input terminal.

[0024] In one embodiment, the DC input terminal includes a positive input terminal and a negative input terminal. The positive input terminal is connected to the positive terminal of the energy storage module, and the negative input terminal is connected to the negative terminal of the energy storage module. The mode switching circuit includes a first switching circuit and a second switching circuit. A first terminal of the first switching circuit is electrically connected to a first input terminal of the PFC switching circuit, a second terminal of the first switching circuit is electrically connected to the positive input terminal, a first terminal of the second switching circuit is electrically connected to a second input terminal of the PFC switching circuit, and a second terminal of the second switching circuit is electrically connected to the negative input terminal.

[0025] In one embodiment, the integrated controller further includes:

[0026] A second voltage conversion circuit, wherein a first terminal of the second voltage conversion circuit is used to connect to a low-voltage battery, and a second terminal of the second voltage conversion circuit is electrically connected to the DC input terminal;

[0027] The second voltage conversion circuit is used to step down the output voltage of the energy storage module and output it to the low-voltage battery to power the low-voltage battery.

[0028] This invention proposes an integrated control system, comprising the integrated controller described in any one of the above claims, and further comprising:

[0029] Controller;

[0030] A pre-charging circuit, wherein the input terminal of the pre-charging circuit is used to connect to the energy storage module, and the output terminal of the pre-charging circuit is electrically connected to the DC input terminal; the controlled terminal of the pre-charging circuit is electrically connected to the controller.

[0031] The controller is configured to control the pre-charging circuit to operate when a power-on control signal is received, so as to provide a pre-charging voltage; and to control the pre-charging circuit to stop operating when the pre-charging voltage reaches a preset voltage threshold.

[0032] In one embodiment, the pre-charging circuit includes:

[0033] A precharge switch and a precharge resistor are provided. The first terminal of the precharge switch is the input terminal of the precharge circuit. The second terminal of the precharge switch is electrically connected to the first terminal of the precharge resistor, and the second terminal of the precharge resistor is electrically connected to the DC input terminal.

[0034] A first main switch, the first end of which is electrically connected to the first end of the precharge switch, and the second end of which is electrically connected to the second end of the precharge resistor;

[0035] The pre-charge resistor is used to limit the current during power-on to a preset current range;

[0036] The controller is configured to control the precharge switch to be closed and the first main switch to be open when a power-on control signal is received, so as to provide a precharge voltage; and to control the precharge switch to be open and the first main switch to be closed when the precharge voltage reaches a preset voltage threshold, so as to output the output voltage of the energy storage module.

[0037] This invention also proposes a control method for an integrated controller, applied to an integrated controller comprising a three-phase bridge arm circuit, a PFC switching circuit, a mode switching circuit, and a voltage conversion circuit; the integrated controller has a charging mode and an operating mode; the control method for the integrated controller includes:

[0038] Obtain the operating mode of the integrated controller;

[0039] In charging mode, the mode switching circuit is controlled to disconnect the electrical connection between the PFC switch circuit and the DC input terminal; in operating mode, the mode switching circuit is controlled to connect the electrical connection between the PFC switch circuit and the DC input terminal to bypass the voltage conversion circuit.

[0040] In charging mode, the three-phase bridge arm circuit and the PFC switch circuit are controlled to operate in rectification mode to rectify the AC power input to the AC input terminal and output DC voltage to the voltage conversion circuit; in operating mode, the three-phase bridge arm circuit and the PFC switch circuit are controlled to operate in inverter mode to invert the DC voltage input to the DC input terminal and output AC voltage.

[0041] The present invention also proposes a control device comprising: a memory, a processor, and a computer program stored in the memory and executable on the processor, the computer program being configured to implement the steps of the control method of the integrated controller as described above.

[0042] The present invention also proposes an electric vehicle, the electric vehicle comprising an integrated controller as described in any of the preceding claims, and / or an integrated control system as described in any of the preceding claims, or a control device as described in the preceding claims.

[0043] This invention proposes an integrated controller, including an AC input terminal and a DC input terminal, a three-phase bridge arm circuit, a PFC switching circuit, a voltage conversion circuit, and a mode switching circuit, which are sequentially connected in series between the AC input terminal and the DC input terminal. The DC input terminal is used to connect an energy storage module; the AC input terminal is used to connect AC power; one end of the mode switching circuit is connected to the input terminal of the PFC switching circuit, and the other end of the mode switching circuit is connected to the DC input terminal. The integrated controller has a charging mode and an operating mode. In the charging mode, the mode switching circuit is used to disconnect the electrical connection between the PFC switching circuit and the DC input terminal; in the operating mode, the mode switching circuit is used to connect the electrical connection between the PFC switching circuit and the DC input terminal to bypass the voltage conversion circuit.

[0044] In practical applications, the mode switching circuit enables the integrated controller to switch between charging mode and operating mode. In charging mode and operating mode, the three-phase bridge arm circuit and PFC switch circuit operate in different states. Specifically, in charging mode, the mode switching circuit disconnects the electrical connection between the PFC switch circuit and the DC input terminal, so that the three-phase bridge arm circuit and PFC switch circuit operate in rectification mode, rectifying the AC power input to the AC input terminal and outputting a DC voltage to the voltage conversion circuit, which then converts the received DC voltage and outputs it. In operating mode, the mode switching circuit connects the electrical connection between the PFC switch circuit and the DC input terminal, bypassing the voltage conversion circuit, so that the three-phase bridge arm circuit and PFC switch circuit operate in inverter mode, inverting the output voltage of the energy storage module input to the DC input terminal and outputting it. Thus, the integrated controller of the present invention can reuse the drive motor switch module used in the existing technology for the drive motor module as part of the switch module of the PFC unit in the OBC, and use it as a three-phase bridge arm circuit, while retaining the other part of the switch module of the PFC unit in the OBC as a PFC switch circuit. In this way, power integration between the motor drive system and the charging system is realized, the integration degree of the integrated controller is improved, and the circuit design complexity and R&D cost are reduced. Attached Figure Description

[0045] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0046] Figure 1 This is a schematic diagram of a module of an embodiment of the integrated controller of the present invention;

[0047] Figure 2 This is a schematic diagram of another embodiment of the integrated controller of the present invention;

[0048] Figure 3 This is a schematic diagram of a module of another embodiment of the integrated controller of the present invention;

[0049] Figure 4 This is a schematic diagram of a module of another embodiment of the integrated controller of the present invention;

[0050] Figure 5 This is a schematic diagram of a module of an embodiment of the integrated control system of the present invention;

[0051] Figure 6 This is a schematic diagram of the power topology of an integrated control system in the prior art;

[0052] Figure 7 This is a power topology diagram of an embodiment of the integrated control system of the present invention;

[0053] Figure 8 This is a working mode diagram of an embodiment of the power topology of the integrated controller of the present invention;

[0054] Figure 9 This is a working mode diagram of yet another embodiment of the power topology of the integrated controller of the present invention;

[0055] Figure 10 This is a working mode diagram of another embodiment of the power topology of the integrated controller of the present invention;

[0056] Figure 11 This is a working mode diagram of another embodiment of the power topology of the integrated controller of the present invention.

[0057] Explanation of icon numbers:

[0058] 10. AC input terminal; 20. DC input terminal; 30. Three-phase bridge arm circuit; 40. PFC switch circuit; 50. Voltage conversion circuit; 60. Mode switching circuit; 70. Motor module; 80. Second voltage conversion circuit; 90. Main controller; 100. Pre-charge circuit.

[0059] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0060] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0061] Currently, the integration of integrated controllers on the market mainly focuses on the integration of high-voltage components in the power domain, with physical integration and semi-deep integration as the primary integration directions. This typically involves integrating multiple functional boards into a single mechanical housing, sharing the housing, wiring harnesses, cooling systems, or some components sharing control circuitry, thereby achieving a compact and unified structure. Even in the area of ​​power topology integration, only the reuse of power topologies between the DC / DC converter and the OBC is achieved, but the integration and reuse of power topologies remains limited, and the integration effect is not significant.

[0062] Therefore, refer to Figure 1 This invention proposes an integrated controller, comprising:

[0063] AC input terminal 10 is used for connecting AC power;

[0064] DC input terminal 20 is used to connect to the energy storage module;

[0065] The three-phase bridge arm circuit 30, the PFC switch circuit 40 and the voltage conversion circuit 50 are connected in series between the AC input terminal 10 and the DC input terminal 20.

[0066] A mode switching circuit 60, one end of which is connected to the input terminal of the PFC switch circuit 40, and the other end of which is connected to the DC input terminal 20;

[0067] The integrated controller has a charging mode and an operating mode. In the charging mode, the mode switching circuit 60 is used to disconnect the electrical connection between the PFC switching circuit 40 and the DC input terminal 20.

[0068] In the operating mode, the mode switching circuit 60 is used to connect the PFC switching circuit 40 and the DC input terminal 20 to bypass the voltage conversion circuit 50.

[0069] In this embodiment, the three-phase bridge arm circuit 30 can be composed of a three-phase bridge circuit consisting of power switching transistors and diodes. The mode switching circuit 60 can be implemented using switching devices such as relays and contactors, or using switching transistors such as transistors, MOSFETs, and IGBTs. The buck converter circuit includes at least one of a boost circuit, a buck circuit, and a buck-boost circuit.

[0070] Specifically, when the integrated controller is in charging mode, the mode switching circuit 60 disconnects the connection between the PFC switching circuit 40 and the DC input terminal 20. The AC power input to the AC input terminal 10 is rectified by the three-phase bridge arm circuit 30, then the PFC switching circuit 40 improves the power factor, and finally the voltage is converted by the voltage conversion circuit 50 before being output to the energy storage module to charge it. The direction of power transmission is as follows: Figure 7 The transmission path 4 is shown in the diagram. When the integrated controller is in operating mode, AC input terminal 10 is not connected to AC power, i.e., it is not connected to the grid voltage. The energy storage module may include a high-voltage power battery, which is usually a lithium-ion battery pack, capable of storing a large amount of electrical energy to provide sufficient power to drive the electric vehicle. At this time, the mode switching circuit 60 disconnects the connection between the PFC switching circuit 40 and the DC input terminal 20, bypassing the voltage conversion circuit 50. The PFC switching circuit 40 and the three-phase bridge arm circuit 30 operate in inverter mode to invert the output voltage of the high-voltage power battery and output three-phase AC power to drive the motor, i.e., converting electrical energy into mechanical energy to provide power for the electric vehicle. The direction of electrical energy transmission in the operating state is as follows: Figure 7 The transmission path is shown in Figure 5.

[0071] It should be noted that the reference Figure 6 , Figure 6This is a power topology diagram of an integrated control system in the prior art, including four parts: a motor module 70, a drive motor controller module, a DC / DC converter, and an OBC (on-board charger). The drive motor controller module controls the motor module 70 and includes a drive motor switch module and a bus capacitor C1. The drive motor switch module controls the current in the motor windings; the bus capacitor C1 stabilizes the DC-side voltage, filters current ripple, and reduces voltage fluctuations. The DC / DC converter performs conversion between any DC voltages, typically converting the output voltage of the energy storage module into the voltage of a low-voltage battery to charge the low-voltage battery of the electric vehicle and power low-voltage electrical appliances. It features Buck and Boost modes. In Buck mode, the DC / DC converter steps down the output voltage of the energy storage module to charge the low-voltage battery or power low-voltage electrical appliances. In Boost mode, the DC / DC converter boosts the voltage of the low-voltage battery to charge the energy storage module, such as a high-voltage power battery, or to meet the needs of high-voltage electrical modules. The OBC is used to implement AC slow charging functionality and consists of two parts: a PFC unit and an HVDCDC unit. The PFC unit (Power Factor Correction Unit) is referenced... Figure 6 The PFC unit comprises four parts: PFC inductor L1, PFC fast transistors S9 / S10 (typically a switching module composed of fast IGBTs and silicon carbide diodes), PFC slow transistors S7 / S8 (typically a switching module composed of slow IGBTs and ordinary diodes), and PFC output capacitor C2. The PFC unit improves the charger's power factor and reduces harmonic pollution to the power grid by converting AC to DC, enabling bidirectional power transmission. The HVDCDC (High Voltage Direct Current Converter) provides electrical isolation between the AC grid side and the vehicle side, while controlling voltage and current to meet a wide range of voltage output conditions and achieve bidirectional power transmission.

[0072] In this embodiment, optionally, the drive motor switching module can be used as the three-phase bridge arm circuit 30, and the slow tube S7 / S8 in the PFC unit in the prior art can be retained as the PFC switching circuit 40. The voltage conversion circuit 50 is the high voltage DC converter mentioned above. In this way, power integration between the motor drive system and the charging system is realized, and the integration degree of the integrated controller is improved.

[0073] In practical applications, the integrated controller of the present invention can reuse the drive motor switch module used in the drive motor module 70 in the prior art as part of the switch module of the PFC unit in the OBC, and use it as the three-phase bridge arm circuit 30. It also retains the other part of the switch module of the PFC unit in the OBC and uses it as the PFC switch circuit 40. In this way, power integration between the motor drive system and the charging system is realized, the integration degree of the integrated controller is improved, and the circuit design complexity and R&D cost are reduced.

[0074] In one embodiment, the integrated controller further includes a motor module 70, a first terminal of which is electrically connected to the AC input terminal 10, and a second terminal of which is electrically connected to the three-phase bridge arm circuit 30.

[0075] In charging mode, the motor module 70 operates in an inductor state to store / release energy; in operating mode, the motor module 70 operates in a winding state to generate a rotating magnetic field when AC power is connected to the AC input terminal 10.

[0076] Understandably, in a motor control system, the three-phase windings, acting as the motor module 70, can generate a rotating magnetic field through the connected three-phase alternating current, causing the rotor to rotate, thereby realizing the rotation of the motor and converting electrical energy into mechanical energy.

[0077] Based on the above embodiments, refer to Figure 6 The PFC unit comprises four parts: PFC inductor L1, PFC fast transistors S9 / S10 (typically a switching module composed of fast IGBTs and silicon carbide diodes), PFC slow transistors S7 / S8 (typically a switching module composed of slow IGBTs and ordinary diodes), and PFC output capacitor C2. The inductor L1 stores and releases energy to convert AC to DC. The rapid switching of the PFC fast transistors S9 / S10 and PFC slow transistors S7 / S8 converts the input AC to DC. In other words, the energy conversion from AC to DC is achieved through the control of the switching transistors. The output capacitor C2 stabilizes the output voltage of the PFC unit, ensuring its stability.

[0078] In this embodiment, during charging mode, the mode switching circuit 60 disconnects the connection between the PFC switching circuit 40 and the DC input terminal 20, and the motor module 70 operates in an inductor state to store / release energy. At this time, the motor module 70 acts as the PFC inductor L1 in the PFC unit, performing energy storage and release processes to achieve the conversion from AC to DC power. Through the rapid switching action of the PFC switching circuit 40, composed of the three-phase bridge arm circuit 30 and the PFC slow tubes S7 / S8, the AC power input from the AC power source is converted to DC power, and after being boosted / buckled / boosted by the voltage conversion circuit 50 (DC / DC), it is output to the DC input terminal 20 to charge the energy storage module. The direction of energy transmission is as follows: Figure 7 The transmission path is shown in Figure 4. In operation mode, the mode switching circuit 60 connects the PFC switching circuit 40 to the DC input terminal 20, bypassing the voltage conversion circuit 50. The motor module 70 operates in winding mode, generating a rotating magnetic field when AC power is applied to the AC input terminal 10. Specifically, the three-phase bridge arm circuit 30 and the PFC switching circuit 40 act as inverter circuits, inverting the output voltage of the energy storage module and outputting it to the motor module 70 to generate a rotating magnetic field, converting electrical energy into mechanical energy to drive the electric vehicle. The direction of electrical energy transmission in operation is as follows: Figure 7 The transmission path is shown in Figure 5.

[0079] It is understood that in this embodiment, the motor module 70 (three-phase stator winding) of the motor drive system in the prior art can be reused as the PFC inductor L1 in the PFC unit to realize power integration between the motor drive system and the charging system, thereby improving the integration of the integrated controller.

[0080] In one embodiment of the present invention, the integrated controller further includes a capacitor, which is connected in series between the PFC switching circuit 40 and the voltage conversion circuit 50;

[0081] In charging mode, the capacitor operates in power factor correction mode; in operating mode, the capacitor operates in DC bus capacitor mode.

[0082] As is understandable, a PFC (Power Factor Correction) unit typically consists of components such as inductors, switching transistors, and capacitors. The capacitors are used to stabilize the output voltage of the PFC unit and reduce voltage fluctuations. By storing and releasing charge, the capacitors can compensate for voltage fluctuations caused by load changes, ensuring the stability of the output voltage.

[0083] In charging mode, the three-phase bridge arm circuit 30 and the PFC switch circuit 40 operate in rectification mode, used to rectify the AC power connected to the AC input terminal 10 and output DC voltage to the voltage conversion circuit 50, so that the voltage conversion circuit 50 converts the received DC voltage and outputs it; in conjunction with the above embodiment, refer to Figure 7 In charging mode, the mode switching circuit 60 disconnects the PFC switching circuit 40 from the DC input terminal 20, and the motor module 70 operates in an inductor state to store / release energy. At this time, the motor module 70 acts as the PFC inductor L1 in the PFC unit, performing the energy storage and release process to achieve the conversion from AC to DC. At this time, the capacitor C1 operates in a power factor correction state, acting as the output capacitor of the original PFC unit to limit the output voltage of the PFC switching circuit 40 within a preset first voltage range. Together with the motor module 70, the three-phase bridge arm circuit 30, and the PFC switching circuit 40, it forms a PFC unit, ensuring that the AC power connected to the AC input terminal 10 is rectified by the three-phase bridge arm circuit 30 and the PFC switching circuit 40 and outputs a stable DC voltage (within the preset first voltage range) to the voltage conversion circuit 50. This allows the voltage conversion circuit 50 to convert the voltage according to a preset voltage ratio and output it to the DC input terminal 20 to charge the energy storage module connected to the DC input terminal 20 or to supply power to the power consumption module connected to the DC input terminal 20. The preset first voltage range and preset voltage ratio are set in advance by the R&D personnel. In operation mode, the mode switching circuit 60 connects the PFC switching circuit 40 to the DC input terminal 20. At this time, capacitor C1 operates as a DC bus capacitor, limiting the output voltage of the energy storage module within the preset second voltage range. The main function of the bus capacitor C1 is to stabilize the DC side voltage of the inverter circuit composed of the PFC switching circuit 40 and the three-phase bridge arm circuit 30, and to filter out high-frequency ripple in the current, providing a stable DC power supply (within the preset second voltage range) for the inverter circuit. The DC power output from the energy storage module to the DC input terminal 20 is first filtered by the bus capacitor to ensure voltage stability. Then, due to the mode switching circuit 60 connecting the PFC switch circuit 40 to the DC input terminal 20, the voltage conversion circuit 50 is bypassed. At this time, the three-phase bridge arm circuit 30 and the PFC switch circuit 40 operate in inverter mode, converting the DC voltage filtered by the bus capacitor C1 into AC voltage for output to the motor module 70. The motor module 70 operates in winding mode, generating a rotating magnetic field when AC power is applied, converting electrical energy into mechanical energy to drive the electric vehicle. The preset first voltage range and preset second voltage range are pre-set by the R&D personnel.

[0084] With the above settings, the output capacitor C2 of the original OBC PFC unit (as shown in the image) Figure 6As shown, the bus capacitor C1 of the drive motor controller module can be reused. Therefore, there is no need to set an additional output capacitor for the PFC unit. The main controller 90 only needs to control the three-phase bridge arm circuit 30 and the PFC switching circuit 40 to switch between rectification and inversion states. Thus, while ensuring the electric vehicle has normal operation and charging functions, power topology reuse eliminates the power topology in the original OBC PFC unit, reducing the size of the integrated controller, lowering R&D costs, and reducing circuit design complexity.

[0085] In one embodiment, the integrated controller further includes:

[0086] The main controller 90 is electrically connected to the controlled terminal of the three-phase bridge arm circuit 30, the controlled terminal of the PFC switch circuit 40, and the controlled terminal of the voltage conversion circuit 50.

[0087] In charging mode, the main controller 90 is used to control the three-phase bridge arm circuit 30 and the PFC switch circuit 40 to work in rectification mode, so as to rectify the AC power connected to the AC input terminal 10 and output DC voltage to the voltage conversion circuit 50, and control the voltage conversion circuit 50 to convert the received DC voltage and output it.

[0088] In operation mode, the main controller 90 is used to control the three-phase bridge arm circuit 30 and the PFC switch circuit 40 to work in inverter mode, so as to output AC voltage after inverting the DC voltage connected to the DC input terminal 20.

[0089] In this embodiment, the main controller 90 can be implemented using MCU, DSP (Digital Signal Processor), FPGA (Field Programmable Gate Array), PLC, SOC (System On Chip), etc.

[0090] refer to Figure 4The control terminals of the main controller 90 can be electrically connected to the controlled terminals of the motor module 70, the three-phase bridge arm circuit 30, the PFC switch circuit 40, the voltage conversion circuit 50, and the mode switching circuit 60, respectively. The main controller 90 can control the operating mode of the integrated controller. For example, the main controller 90 (such as the vehicle control unit, VCU) determines whether the electric vehicle is in operation or charging state by monitoring signals from various vehicle sensors. In practical applications, when AC input terminal 10 is connected to AC power and DC input terminal 20 is connected to the energy storage module, i.e., when the charging plug is inserted into the vehicle, the detection signal in the charging interface is sent to the main controller 90, so that the main controller 90 determines that the electric vehicle needs to be charged. It then connects to the single-phase (three-phase) AC power in the AC charging pile through AC input terminal 10 to charge the energy storage module. If AC input terminal 10 is not connected to AC power, the main controller 90 determines that the electric vehicle needs to run based on the trigger signal triggered by the user. For example, when the driver presses the start button and depresses the accelerator pedal, the accelerator pedal position sensor and vehicle speed sensor will send corresponding signals to the main controller 90. At this time, the energy storage module (such as a high-voltage power battery) needs to be used as the power source.

[0091] Specifically, refer to Figure 7 In charging mode, the main controller 90 controls the mode switching circuit 60 to disconnect the connection between the PFC switching circuit 40 and the DC input terminal 20, and controls the motor module 70 to operate in an inductor state for storing / releasing energy. This allows the motor module 70 to act as the PFC inductor L1 in the PFC unit, performing energy storage and release processes to achieve the conversion from AC to DC. The main controller 90 controls the three-phase bridge arm circuit 30 and the PFC switching circuit 40 to be in rectification mode. Through rapid switching, it converts the AC input from the AC power supply terminal into DC, and controls the voltage conversion circuit 50 (DC / DC) to perform boost / buck / boost-buck processing before outputting it to the DC input terminal 20 to charge the energy storage module. The direction of energy transmission is as follows: Figure 7 The transmission path 4 is shown in the diagram. In operation mode, the main controller 90 controls the mode switching circuit 60 to connect the PFC switch circuit 40 and the DC input terminal 20, bypasses the voltage conversion circuit 50, and controls the motor module 70 to work in the winding state, so that it generates a rotating magnetic field when AC power is applied. That is, the main controller 90 controls the three-phase bridge arm circuit 30 and the PFC switch circuit 40 to be in inverter mode. As an inverter circuit, the output voltage of the energy storage module is filtered by capacitor C1 and then output to the inverter circuit, so as to invert it and output it to the motor module 70 to generate a rotating magnetic field, converting electrical energy into mechanical energy to drive the electric vehicle.

[0092] In practical applications, the PFC inductor L1 of the PFC unit in the original charging system can reuse the motor module 70 (three-phase stator windings (La / Lb / Lc)) of the motor drive system. The fast transistors S9-S10 of the original PFC unit can reuse the drive motor switch modules (S1-S6) in the drive motor controller module as the three-phase bridge arm circuit 30 in the integrated controller of this invention. The original PFC output capacitor C2 can reuse the bus capacitor C1 in the drive motor controller module. Only the slow transistors S7 and S8 of the original OBC PFC unit are retained as the PFC switch circuit 40 in the integrated controller of this invention. In charging mode, the main controller 90 controls the PFC switch circuit 40 and the three-phase bridge arm circuit 30 to work in rectification mode, and outputs the AC power connected to the AC input terminal 10 after rectification. In operating mode, the main controller 90 controls the PFC switch circuit 40 and the three-phase bridge arm circuit 30 to work in inverter mode, and outputs the AC voltage connected to the DC input terminal 20 to the motor module 70 after inverter processing. Thus, the integrated controller of this invention achieves power topology reuse in the PFC unit, except for the two slow transistors, by reusing the three-phase stator windings, drive motor switching module, and bus capacitor in the drive motor controller module. In this way, by reusing some modules of the existing motor drive system to implement the PFC function, the number of additional components that need to be equipped separately for the PFC unit is reduced, thereby reducing design costs and size.

[0093] In one embodiment, the PFC switching circuit 40 includes an upper bridge switching transistor and a lower bridge switching transistor, the motor module 70 includes a three-phase winding, and the three-phase bridge arm circuit 30 includes a first bridge arm circuit, a second bridge arm circuit, and a third bridge arm circuit; the midpoint of the first bridge arm circuit, the midpoint of the second bridge arm circuit, and the midpoint of the third bridge arm circuit are respectively connected to the three-phase winding.

[0094] In charging mode, the upper and lower bridge arm switches of any one of the first bridge arm circuit, the second bridge arm circuit, and the third bridge arm circuit are turned on / off at a first preset frequency to form a circuit with the motor module 70, so that the motor module 70 stores / releases energy.

[0095] In operation mode, the upper and lower bridge arm switches in the first, second, and third bridge arm circuits are turned on / off at a second preset frequency.

[0096] In each bridge arm circuit, the upper or lower bridge arm switching transistor is composed of a power switching transistor and a diode.

[0097] In this embodiment, the motor module 70 includes three-phase windings La, Lb, and Lc, which operate in an inductor state in charging mode and in a winding state in running mode. Each bridge arm circuit in the three-phase bridge arm circuit 30 includes an upper bridge arm switch and a lower bridge arm switch. In this embodiment, both the upper and lower bridge arm switches are composed of a power switch IGBT and a diode connected together. In charging mode, the main controller 90 controls the upper and lower bridge arm switches of any one of the first, second, and third bridge arm circuits to alternately turn on / off at a first preset frequency, so that the upper and lower bridge arm switches corresponding to those in the PFC switch circuit 40 operate in a rectification state, thereby rectifying the AC power connected to the AC input terminal 10 and outputting it to the DC input terminal 20 to power the energy storage module or the power consumption module. It should be noted that in charging mode, the conduction state of each bridge arm circuit in the three-phase bridge arm circuit 30 depends on the charging power demand. When the charging power demand is high, it is usually necessary to fully utilize all bridge arm circuits to improve charging efficiency and power handling capacity. Therefore, the main controller 90 can control all the upper and lower bridge arm switches in the three-phase bridge arm circuit 30 to turn on / off at a first preset frequency to maximize the charging power. This ensures that the three-phase windings La, Lb, and Lc all participate in the energy conversion process. That is, the upper and lower bridge arm switches in each bridge arm circuit will alternately conduct as needed to achieve energy conversion and storage. When the charging power demand is low, the upper and lower bridge arm switches of any one phase bridge arm circuit can be turned on / off at the first preset frequency to form a loop with the motor module 70, so that the motor module 70 stores / releases energy. For example, if the upper bridge switch S1 of the first bridge arm circuit is turned on, then the La winding will participate in the energy conversion process. Furthermore, in operation mode, the upper and lower bridge arm switches in the first, second, and third bridge arm circuits are turned on / off at a second preset frequency. This allows them to operate simultaneously with the upper and lower bridge switches in the PFC circuit in inverter mode, converting the DC voltage input to the DC input terminal 20 and outputting it to the motor module 70, thus achieving the conversion between electrical energy and mechanical energy. The first and second preset frequencies are pre-set by the researchers.

[0098] Optionally, the DC input terminal 20 includes a positive input terminal and a negative input terminal. The positive input terminal is connected to the positive terminal of the energy storage module, and the negative input terminal is connected to the negative terminal of the energy storage module. The mode switching circuit 60 includes a first switching circuit and a second switching circuit. The first terminal of the first switching circuit is electrically connected to the first input terminal of the PFC switching circuit 40, the second terminal of the first switching circuit is electrically connected to the positive input terminal, the first terminal of the second switching circuit is electrically connected to the second input terminal of the PFC switching circuit 40, and the second terminal of the second switching circuit is electrically connected to the negative input terminal.

[0099] In this embodiment, both the first and second switching circuits can be implemented using switching devices such as contactors and relays, or using switching transistors such as transistors, MOSFETs, and IGBTs.

[0100] Specifically, refer to Figure 7 The positive input terminal of the DC input terminal 20 is connected to the positive terminal of the energy storage module, and the negative input terminal is connected to the negative terminal of the energy storage module, forming a closed loop with the AC charging unit, motor module 70, three-phase bridge arm circuit 30, and PFC switch circuit 40. Taking the first and second switch circuits as relays as an example, K4 is the first switch circuit, located between the first input terminal and the positive input terminal of the PFC switch circuit 40, and K5 is the second switch circuit, located between the second input terminal and the negative input terminal of the PFC switch circuit 40; the switching transistors S7 and S8 constitute the PFC switch circuit 40, which can be the slow transistors S7 and S8 in the original PFC unit; the original drive motor switch module serves as the three-phase bridge arm circuit 30, and the three-phase stator windings in the original motor drive system serve as the motor module 70.

[0101] In accordance with the above embodiments, when the electric vehicle needs to operate in running mode (driving), the main controller 90 closes contactors K4 and K5 in the mode switching circuit 60 to bypass the voltage conversion circuit 50 (HVDCDC), controlling the three-phase bridge arm circuit 30 and PFC switching circuit 40 to be in inverter mode. As an inverter circuit, the output voltage of the energy storage module is filtered by capacitor C1 and then output to the inverter circuit. The filtered DC voltage is then inverted and output to the motor module 70, generating a rotating magnetic field that converts electrical energy into mechanical energy to drive the electric vehicle. When the vehicle needs to operate in charging mode, the main controller 90 opens contactors K4 and K5 in the mode switching circuit 60 and controls the three-phase bridge arm circuit 30 and PFC switching circuit 40 to be in rectification mode, converting the AC power from the grid side into DC power. After being boosted and / or bucked by the voltage conversion circuit 50 according to a preset voltage ratio, the DC power is output to the energy storage module or the on-board power module.

[0102] In this embodiment, in charging mode, after reusing the three-phase stator windings La / Lb / Lc, the drive motor switching module, and the bus capacitor C1, when the circuit is operating stably, within a single power frequency cycle, the PFC switching circuit 40 and the three-phase bridge arm inverter circuit have four operating modes (a, b, c, d). The different modes and current flows are as follows: Figures 8 to 11 As shown.

[0103] refer to Figure 7 In the three-phase bridge arm circuit 30, switches S1 and S4 constitute the first bridge arm circuit, switches S3 and S6 constitute the second bridge arm circuit, and switches S5 and S2 constitute the third bridge arm circuit. This embodiment specifically uses the first bridge arm circuit S1 and S4 as an example for explanation. (Reference) Figure 8 In operating mode a: the AC voltage Vg connected to AC input terminal 10, together with the inductor La / Lb, the lower bridge arm switch S4 in the three-phase bridge arm circuit 30, and the lower bridge arm switch S8 in the PFC switching circuit 40, forms a conduction loop, charging the inductor and storing energy. Simultaneously, capacitor C1 supplies power to the load; at this time, the output voltage decreases. (Reference) Figure 9 In operating mode b, the AC voltage Vg connected to AC input terminal 10, the inductor La / Lb, and switches S1 and S8 form a conducting loop, simultaneously charging capacitor C1 and the load. At this time, the inductor is discharging, and capacitor C1 is charging, therefore the output voltage at DC input terminal 20 increases. (Reference) Figure 10 In operating mode c: The AC voltage Vg connected to AC input terminal 10, together with inductor La / Lb, switching transistor S1, and the lower bridge arm switching transistor S7 in PFC switching circuit 40, forms a conduction loop, charging the inductor and storing energy. Simultaneously, capacitor C1 supplies power to the load, thus reducing the output voltage. (Reference) Figure 11 Operating mode d: The AC voltage Vg connected to AC input terminal 10 and the inductors La / Lb charge capacitor C1 and the load through the conduction circuit formed by S4 and S7. At this time, the inductor discharges and charges the output capacitor C1, so the output voltage rises. It should be noted that when the input voltage Vg is greater than zero, the PFC switching circuit 40 and the three-phase bridge arm inverter circuit operate in operating modes a and b; when the input voltage Vg is less than zero, the PFC switching circuit 40 and the three-phase bridge arm inverter circuit operate in operating modes c and d.

[0104] With the above settings, in charging mode, the integrated controller of this invention can effectively convert AC power to DC power to charge the energy storage module of the electric vehicle. In operating mode, it can convert the DC power from the energy storage module to AC power to drive the motor and thus propel the vehicle. By integrating the OBC slow charging function and the motor drive function into the same integrated controller, the complexity and size of the circuit design are reduced.

[0105] In one embodiment, reference Figure 3 The integrated controller further includes:

[0106] The second voltage conversion circuit 80 has a first terminal for connecting to a low-voltage battery and a second terminal for being electrically connected to the DC input terminal 20.

[0107] The second voltage conversion circuit 80 is used to step down the output voltage of the energy storage module and output it to the low-voltage battery to power the low-voltage battery.

[0108] In this embodiment, the second voltage conversion circuit 80 can be implemented using at least one of a boost circuit, a buck circuit, or a buck-boost circuit.

[0109] Specifically, the second voltage conversion circuit 80 can output the output voltage of the energy storage module according to a preset voltage ratio to the low-voltage battery or other low-voltage power modules to supply power to the low-voltage battery or other power modules. (Reference) Figure 7 The DC / DC converter (DC-DC converter) steps down the voltage of the high-voltage power battery connected to the DC input terminal 20 to a preset voltage value and then outputs it to the low-voltage battery to charge it. Simultaneously, it can also step down the voltage of the high-voltage power battery connected to the DC input terminal 20 and output it to the low-voltage power module to power the low-voltage electrical appliances in the electric vehicle. In Buck mode, the energy transfer path is high-voltage power battery → DC / DC converter → low-voltage battery, as follows: Figure 7 The energy transfer path is shown in Figure 6. When the electric vehicle needs to use the energy from the low-voltage battery to support the power demand of the high-voltage system, the second voltage conversion circuit 80 can boost the voltage of the low-voltage battery to charge the high-voltage battery or meet the needs of the high-voltage system. Energy transfer path: Low-voltage battery → DC / DC → High-voltage power battery. The energy transfer direction in Boost mode is opposite to the transmission path in Buck mode.

[0110] The second voltage conversion circuit 80 provides electric vehicles with flexible energy conversion capabilities through buck and boost functions, enabling it to meet the power needs of low-voltage battery charging or high-voltage systems in different application scenarios. This improves the energy conversion efficiency of the integrated controller. Furthermore, using a DC / DC converter as the second voltage conversion circuit 80 reduces the size of the integrated controller.

[0111] The working principle of the integrated controller of the present invention will be explained below with reference to the above embodiments:

[0112] refer to Figure 7In charging mode, the main controller 90 controls the first switch circuit K4 and the second switch circuit K5 in the mode switching circuit 60 to be in the off state, and controls the motor module 70 (three-phase stator windings La / Lb / Lc) to operate in an inductive state for storing / releasing energy. It also controls the three-phase bridge arm circuit 30 and the PFC switch circuit 40, composed of the upper bridge arm switch S7 and the lower bridge arm switch S8, to operate in a rectification state. This rectifies the AC power input from the AC input terminal 10 and outputs a DC voltage to the voltage conversion circuit 50 (HVDCDC), so that the voltage conversion circuit 50 can convert the received DC voltage... After voltage conversion, the output is processed. At this time, capacitor C1 operates in power factor correction mode, serving as the output capacitor of the original PFC unit. It limits the output voltage of the three-phase bridge arm circuit 30 and the PFC switching circuit 40 to a preset first voltage range. This ensures that the AC power connected to AC input terminal 10, after rectification by the three-phase bridge arm circuit 30 and the PFC switching circuit 40, outputs a stable DC voltage (within the preset first voltage range) to the voltage conversion circuit 50. The voltage conversion circuit 50 then performs voltage conversion according to a preset voltage ratio and outputs the voltage to DC input terminal 20 to charge the energy storage module connected to DC input terminal 20. The preset first voltage range and preset voltage ratio are set in advance by the R&D personnel. In operation mode, the main controller 90 controls the first switch circuit K4 and the second switch circuit K5 in the mode switching circuit 60 to be closed, thereby connecting the PFC switch circuit 40 to the DC input terminal 20. The motor module 70 operates in inductive mode. The main controller 90 controls the three-phase bridge arm circuit 30 and the PFC switch circuit 40, composed of the upper bridge arm switch S7 and the lower bridge arm switch S8, to operate in inverter mode. At this time, the capacitor C1 operates as a DC bus capacitor, limiting the output voltage of the energy storage module within a preset second voltage range. The main function of the bus capacitor C1 is to stabilize the DC side voltage of the inverter circuit composed of the PFC switch circuit 40 and the three-phase bridge arm circuit 30, and to filter out high-frequency ripple in the current, providing a stable DC power supply (within the preset second voltage range) for the inverter circuit. The DC power output from the energy storage module to the DC input terminal 20 is first filtered by the bus capacitor to ensure the stability of the DC voltage. Then, the three-phase bridge arm circuit 30 and the PFC switch circuit 40 invert the DC voltage filtered by the bus capacitor C1 and output AC voltage to the motor module 70. Since the motor module 70 is in the winding state, when AC power is connected, it generates a rotating magnetic field, which converts electrical energy into mechanical energy to drive the electric vehicle.

[0113] In practical applications, the integrated controller proposed in this invention reuses the three-phase stator windings in the original motor drive system as the PFC inductor in the original charging system's PFC unit, reuses the bus capacitor as the output capacitor in the original PFC unit, and reuses the drive motor switching module as part of the switching transistors in the PFC unit, together with the PFC switching circuit 40, to form the entire PFC unit. While ensuring normal vehicle operation and charging functionality, the power topology of the original PFC unit is eliminated, significantly expanding the cost reduction potential of the entire vehicle and meeting the requirements for miniaturization, lightweighting, and low cost of the vehicle's high-voltage components.

[0114] The present invention also proposes an integrated control system, which includes an integrated controller as described above, with reference to... Figure 5 It also includes:

[0115] Controller;

[0116] A pre-charging circuit 100, the input terminal of which is used to connect to an energy storage module, the output terminal of which is electrically connected to the DC input terminal 20; and the controlled terminal of the pre-charging circuit 100 is electrically connected to the controller.

[0117] The controller is configured to control the pre-charging circuit 100 to operate when a power-on control signal is received, so as to provide a pre-charging voltage; and to control the pre-charging circuit 100 to stop operating when the pre-charging voltage reaches a preset voltage threshold.

[0118] In this embodiment, the controller can be implemented using MCU, DSP (Digital Signal Processor), FPGA (Field Programmable Gate Array), PLC, SOC (System On Chip), etc.

[0119] It should be noted that, in order to prevent excessive voltage spikes and inrush currents from occurring when the energy storage module (such as a high-voltage power battery) is directly connected to the load, which could damage the internal components of the integrated controller and the various power-consuming modules, subjecting them to overvoltage and overcurrent surges, a pre-charging circuit 100 is provided. This circuit operates during the high-voltage power-on process to reduce voltage spikes, thereby protecting the integrated controller and the power-consuming modules.

[0120] In this embodiment, the pre-charging circuit 100 includes:

[0121] A precharge switch and a precharge resistor are provided. The first end of the precharge switch is the input terminal of the precharge circuit 100. The second end of the precharge switch is electrically connected to the first end of the precharge resistor. The second end of the precharge resistor is electrically connected to the DC input terminal 20.

[0122] A first main switch, the first end of which is electrically connected to the first end of the precharge switch, and the second end of which is electrically connected to the second end of the precharge resistor;

[0123] The pre-charge resistor is used to limit the current during power-on to a preset current range;

[0124] The controller is configured to control the precharge switch to be closed and the first main switch to be open when a power-on control signal is received, so as to provide a precharge voltage; and to control the precharge switch to be open and the first main switch to be closed when the precharge voltage reaches a preset voltage threshold, so as to output the output voltage of the energy storage module.

[0125] It should be noted that the integrated control system also includes a second main switch, the first end of which is electrically connected to the DC input terminal 20, and the second end of which is electrically connected to the second end of the mode switching circuit 60.

[0126] The controller is used to control the second main switch to be closed when a power-on control signal is received, so as to form a power supply circuit.

[0127] Specifically, K1 is the first main switch, R1 is the pre-charge resistor, K3 is the pre-charge switch, and K2 is the second main switch. Figure 7 As shown, the pre-charging circuit 100, the second main switch, and the energy storage module constitute a high-voltage battery unit. K1 is initially open (when not powered on). When the electric vehicle starts with high voltage power on, the controller receives the power-on control signal and controls the pre-charging switch K3 and the second main switch K2 to close. At this time, the pre-charging circuit 100 begins to work, allowing current to flow through the pre-charging resistor R1 to charge the capacitor in the load circuit, passing a pre-charging voltage to gradually increase the voltage across the capacitor. The pre-charging resistor R1 is used to limit the charging current within a preset current range, thus avoiding damage to the load from voltage spikes and inrush currents. When the capacitor is charged to a certain level (when the pre-charging voltage reaches the preset voltage threshold), the controller controls the pre-charging switch K3 to open and the first main switch K1 to close, allowing the high-voltage power battery to directly connect to the load circuit and supply power to the high-voltage load of the vehicle. It should be noted that the preset current range and preset voltage threshold are set in advance by the R&D personnel. The power-on control signal can be the detection signal output by each sensor or the signal output by an external terminal connected to the controller.

[0128] Through the above settings, the pre-charging circuit 100 can limit the power-on current by using the pre-charging resistor, avoiding the large current surge at the moment of power-on and protecting sensitive components in the high-voltage load of the vehicle. The pre-charging process reduces aging of components caused by large current surges, extends their service life, and thus improves the reliability of the integrated control system.

[0129] It is worth noting that since the integrated control system of the present invention includes the aforementioned integrated controller, the embodiments of the integrated control system of the present invention include all the technical solutions of all the embodiments of the aforementioned integrated controller, and the technical effects achieved are exactly the same, so they will not be repeated here.

[0130] This invention also proposes a control method for an integrated controller, applied to an integrated controller comprising a three-phase bridge arm circuit 30, a PFC switching circuit 40, a mode switching circuit 60, and a voltage conversion circuit 50; the integrated controller has a charging mode and an operating mode; the control method for the integrated controller includes:

[0131] Obtain the operating mode of the integrated controller;

[0132] In charging mode, the mode switching circuit 60 is controlled to disconnect the electrical connection between the PFC switch circuit 40 and the DC input terminal 20; in operating mode, the mode switching circuit 60 is controlled to connect the electrical connection between the PFC switch circuit 40 and the DC input terminal 20 to bypass the voltage conversion circuit 50.

[0133] In charging mode, the three-phase bridge arm circuit 30 and the PFC switch circuit 40 are controlled to operate in rectification mode so as to rectify the AC power connected to the AC input terminal 10 and output DC voltage to the voltage conversion circuit 50; in operating mode, the three-phase bridge arm circuit 30 and the PFC switch circuit 40 are controlled to operate in inverter mode so as to invert the DC voltage connected to the DC input terminal 20 and output AC voltage.

[0134] In this embodiment, the control method of the integrated controller of the present invention can be applied to a control device for an electric vehicle. The control device includes a memory, a processor, and a computer program stored in the memory and executable on the processor. The computer program is configured to implement the steps of the control method of the integrated controller as described above. The control device can be implemented using a main controller 90, such as an MCU, DSP (Digital Signal Processor), FPGA (Field Programmable Gate Array), PLC, or SOC (System on Chip).

[0135] In accordance with the above embodiments, the three-phase bridge arm circuit, PFC switch circuit, and voltage conversion circuit are sequentially connected in series between the AC input terminal and the DC input terminal. The control device can first obtain the operating mode of the integrated controller, for example, by monitoring the signals of various sensors of the vehicle through the vehicle control unit (VCU) to determine whether the electric vehicle is in operation or charging mode. In charging mode, the control device controls the mode switching circuit 60 to disconnect the connection between the PFC switch circuit 40 and the DC input terminal 20, and controls the motor module 70 to operate in an inductor state for storing / releasing energy, so that the motor module 70 acts as the PFC inductor L1 in the PFC unit, performing the energy storage and release process, realizing the conversion from AC to DC power. The control device also controls the three-phase bridge arm circuit 30 and the PFC switch circuit 40 to be in a rectification state, converting the AC power input from the AC power supply terminal into DC power through a fast switching action, and controls the voltage conversion circuit 50 (DC / DC) to perform boost / buck / boost-buck processing before outputting it to the DC input terminal 20 to charge the energy storage module; the direction of power transmission is as follows. Figure 7 The transmission path 4 is shown in the diagram. In operation mode, the control device controls the mode switching circuit 60 to connect the PFC switch circuit 40 and the DC input terminal 20, bypasses the voltage conversion circuit 50, and controls the motor module 70 to work in the winding state, so that it generates a rotating magnetic field when AC power is applied. It also controls the three-phase bridge arm circuit 30 and the PFC switch circuit 40 to work in the inverter state. As an inverter circuit, the output voltage of the energy storage module is filtered by capacitor C1 and then output to the inverter circuit. The inverter circuit inverts the voltage and outputs it to the motor module 70, generating a rotating magnetic field, converting electrical energy into mechanical energy, and driving the electric vehicle.

[0136] In practical applications, the PFC and inverter functions can be achieved simply by controlling the three-phase bridge arm circuit 30 and the PFC switching circuit 40 to switch between rectification and inversion states via a control device. While ensuring the electric vehicle has normal operating and charging capabilities, power topology reuse eliminates the power topology in the original OBC PFC unit, reducing the size of the integrated controller, lowering R&D costs, and simplifying circuit design.

[0137] The present invention also proposes a control device comprising: a memory, a processor, and a computer program stored in the memory and executable on the processor, the computer program being configured to implement the steps of the control method of the integrated controller as described above.

[0138] It is worth noting that since the control device of the present invention is based on the control method of the integrated controller described above, the embodiments of the control device of the present invention include all the technical solutions of all embodiments of the control method of the integrated controller described above, and the technical effects achieved are exactly the same, so they will not be repeated here.

[0139] The present invention proposes an electric vehicle, the electric vehicle comprising an integrated controller as described in any of the preceding claims, and / or an integrated control system as described in any of the preceding claims, or a control device as described in the preceding claims.

[0140] Since the electric vehicle of the present invention includes the aforementioned integrated controller or control device, the embodiments of the electric vehicle of the present invention include all the technical solutions of all embodiments of the aforementioned integrated controller or control device, and the technical effects achieved are exactly the same, so they will not be repeated here.

[0141] The above description is merely an optional embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention's specification and drawings under the inventive concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. An integrated controller, characterized in that, include: AC input terminal, used for connecting to AC power; DC input terminal, used to connect to energy storage module; The three-phase bridge arm circuit, the PFC switch circuit, and the voltage conversion circuit are connected in series between the AC input terminal and the DC input terminal. A mode switching circuit, one end of which is connected to the input terminal of the PFC switch circuit, and the other end of which is connected to the DC input terminal; The integrated controller has a charging mode and an operating mode. In the charging mode, the mode switching circuit is used to disconnect the electrical connection between the PFC switching circuit and the DC input terminal. In operation mode, the mode switching circuit is used to connect the PFC switching circuit to the DC input terminal to bypass the voltage conversion circuit.

2. The integrated controller as described in claim 1, characterized in that, The integrated controller also includes a motor module, the first end of which is electrically connected to the AC input terminal, and the second end of which is electrically connected to the three-phase bridge arm circuit. In charging mode, the motor module operates in an inductive state to store / release energy; In operation mode, the motor module operates in winding state, which generates a rotating magnetic field when AC power is connected to the AC input terminal.

3. The integrated controller as described in claim 1, characterized in that, The integrated controller also includes a capacitor, which is connected in series between the PFC switching circuit and the voltage conversion circuit; In charging mode, the capacitor operates in power factor correction mode; in operating mode, the capacitor operates in DC bus capacitor mode.

4. The integrated controller as described in claim 1, characterized in that, In charging mode, the three-phase bridge arm circuit and the PFC switch circuit operate in rectification mode, which is used to rectify the AC power connected to the AC input terminal and output DC voltage to the voltage conversion circuit, so that the voltage conversion circuit can convert the received DC voltage and output it. In operation mode, the three-phase bridge arm circuit and the PFC switch circuit operate in inverter mode, which is used to invert the DC voltage connected to the DC input terminal and output AC voltage.

5. The integrated controller as described in claim 2, characterized in that, The PFC switching circuit includes an upper bridge switch and a lower bridge switch, the motor module includes a three-phase winding, and the three-phase bridge arm circuit includes a first bridge arm circuit, a second bridge arm circuit, and a third bridge arm circuit; the midpoint of the first bridge arm circuit, the midpoint of the second bridge arm circuit, and the midpoint of the third bridge arm circuit are respectively connected to the three-phase winding. In charging mode, the upper and lower bridge arm switches of any one of the first bridge arm circuit, the second bridge arm circuit, and the third bridge arm circuit are turned on / off at a first preset frequency to form a circuit with the motor module, so that the motor module stores / releases energy. In operation mode, the upper and lower bridge arm switches in the first, second, and third bridge arm circuits are turned on / off at a second preset frequency.

6. The integrated controller as described in any one of claims 1-5, characterized in that, The integrated controller also includes: The main controller is electrically connected to the controlled terminal of the three-phase bridge arm circuit, the controlled terminal of the PFC switch circuit, and the controlled terminal of the voltage conversion circuit. In charging mode, the main controller is used to control the three-phase bridge arm circuit and the PFC switch circuit to operate in rectification mode, so as to rectify the AC power connected to the AC input terminal and output DC voltage to the voltage conversion circuit, and control the voltage conversion circuit to convert the received DC voltage and output it. In operation mode, the main controller is used to control the three-phase bridge arm circuit and the PFC switch circuit to operate in inverter mode, so as to output AC voltage after inverting the DC voltage connected to the DC input terminal.

7. The integrated controller as described in any one of claims 1-5, wherein the DC input terminal includes a positive input terminal and a negative input terminal, the positive input terminal is connected to the positive terminal of the energy storage module, the negative input terminal is connected to the negative terminal of the energy storage module, the mode switching circuit includes a first switching circuit and a second switching circuit, a first terminal of the first switching circuit is electrically connected to the first input terminal of the PFC switching circuit, a second terminal of the first switching circuit is electrically connected to the positive input terminal, a first terminal of the second switching circuit is electrically connected to the second input terminal of the PFC switching circuit, and a second terminal of the second switching circuit is electrically connected to the negative input terminal.

8. The integrated controller as described in any one of claims 1-5, characterized in that, The integrated controller also includes: A second voltage conversion circuit, wherein a first terminal of the second voltage conversion circuit is used to connect to a low-voltage battery, and a second terminal of the second voltage conversion circuit is electrically connected to the DC input terminal; The second voltage conversion circuit is used to step down the output voltage of the energy storage module and output it to the low-voltage battery to power the low-voltage battery.

9. An integrated control system, characterized in that, The integrated control system includes the integrated controller as described in any one of claims 1 to 8, and further includes: Controller; A pre-charging circuit, wherein the input terminal of the pre-charging circuit is used to connect to the energy storage module, and the output terminal of the pre-charging circuit is electrically connected to the DC input terminal; the controlled terminal of the pre-charging circuit is electrically connected to the controller. The controller is configured to control the pre-charging circuit to operate when a power-on control signal is received, so as to provide a pre-charging voltage; and to control the pre-charging circuit to stop operating when the pre-charging voltage reaches a preset voltage threshold.

10. The integrated control system as described in claim 9, characterized in that, The pre-charging circuit includes: A precharge switch and a precharge resistor are provided. The first terminal of the precharge switch is the input terminal of the precharge circuit. The second terminal of the precharge switch is electrically connected to the first terminal of the precharge resistor, and the second terminal of the precharge resistor is electrically connected to the DC input terminal. A first main switch, the first end of which is electrically connected to the first end of the precharge switch, and the second end of which is electrically connected to the second end of the precharge resistor; The pre-charge resistor is used to limit the current during power-on to a preset current range; The controller is configured to control the precharge switch to be closed and the first main switch to be open when a power-on control signal is received, so as to provide a precharge voltage; and to control the precharge switch to be open and the first main switch to be closed when the precharge voltage reaches a preset voltage threshold, so as to output the output voltage of the energy storage module.

11. A control method for an integrated controller, applied to an integrated controller, the integrated controller comprising a three-phase bridge arm circuit, a PFC switching circuit, a mode switching circuit, and a voltage conversion circuit; the integrated controller having a charging mode and an operating mode; characterized in that, The control method of the integrated controller includes: Obtain the operating mode of the integrated controller; In charging mode, the mode switching circuit is controlled to disconnect the electrical connection between the PFC switch circuit and the DC input terminal; in operating mode, the mode switching circuit is controlled to connect the electrical connection between the PFC switch circuit and the DC input terminal to bypass the voltage conversion circuit. In charging mode, the three-phase bridge arm circuit and the PFC switch circuit are controlled to operate in rectification mode to rectify the AC power input to the AC input terminal and output DC voltage to the voltage conversion circuit; in operating mode, the three-phase bridge arm circuit and the PFC switch circuit are controlled to operate in inverter mode to invert the DC voltage input to the DC input terminal and output AC voltage.

12. A control device, characterized in that, The control device includes: a memory, a processor, and a computer program stored in the memory and executable on the processor, the computer program being configured to implement the steps of the control method of the integrated controller as claimed in claim 11.

13. An electric vehicle, characterized in that, The electric vehicle includes an integrated controller as described in any one of claims 1 to 8, and / or an integrated control system as described in any one of claims 9 to 10, or a control device as described in claim 12.

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