Magnetic core assembly, motor controller, electric drive system, and vehicle

Abstract

The application discloses a magnetic core assembly, a motor controller, an electric drive system and a vehicle. The magnetic core assembly comprises a body and a magnetic core component, the body is provided with a first positioning portion and a first connecting hole; the magnetic core component is connected with the body, and the magnetic core component is arranged correspondingly to the first connecting hole. The magnetic core assembly of the application does not arrange a copper bar, reduces the size of parts, improves the power density of the motor controller, and saves production cost.

Description

Technical Field

[0001] This invention belongs to the field of vehicle technology, specifically relating to a magnetic core assembly, a motor controller, an electric drive system, and a vehicle. Background Technology

[0002] The magnetic core assembly is a control component in the motor controller. It converts the current signal from the power module output connector in the motor controller into a magnetic signal by focusing magnetic field lines.

[0003] In related technologies, a copper busbar is provided in the magnetic core assembly. The copper busbar passes through the magnetic core component and is electrically connected to the output connector of the power module. The magnetic core component reflects the current of the power module output terminal by detecting the current of the copper busbar in the magnetic core assembly. When a copper busbar is provided in the magnetic core assembly, the component size is larger and the cost is higher. Summary of the Invention

[0004] The present invention aims to at least partially solve one of the technical problems in the related art.

[0005] Therefore, embodiments of the present invention propose a magnetic core assembly that eliminates the need for copper busbars, reduces the size of the parts, increases the power density of the motor controller, and saves production costs.

[0006] An embodiment of the present invention further proposes a motor controller.

[0007] An embodiment of the present invention further proposes an electric drive system.

[0008] An embodiment of the present invention also proposes a vehicle.

[0009] A magnetic core assembly according to an embodiment of the present invention includes:

[0010] The body has a first positioning part and a first connecting hole;

[0011] A magnetic core component is connected to the body and is arranged corresponding to the first connection hole, which is used to plug into the output terminal of the power module.

[0012] The magnetic core assembly of this invention provides a first connection hole in the main body, which is then plugged into the output terminal of the power module. The magnetic core component directly detects the current magnitude at the output terminal of the power module plugged into the first connection hole. Copper busbars are no longer arranged in the main body, eliminating the need for electrical connection between the copper busbars and the output terminal of the power module. Furthermore, it eliminates the need to detect the current magnitude on the copper busbars to reflect the current magnitude at the output terminal of the power module, thereby reducing the size of the components and saving production costs.

[0013] In some embodiments, the first positioning part is a positioning hole, and the magnetic core assembly further includes a bushing. The bushing is connected to the body, and the bushing and the positioning hole are coaxially arranged. The bushing is disposed at one end of the positioning hole.

[0014] In some embodiments, the positioning hole has a positioning segment and a guide segment arranged sequentially along its assembly direction, the cross-sectional size of the guide segment gradually increasing from the end closer to the positioning segment to the end farther away from the positioning segment.

[0015] In some embodiments, the bushing includes a first body and a boss, the boss being connected to the outer wall surface of the first body and the boss being embedded in the body.

[0016] In some embodiments, the extending direction of the first connecting hole is orthogonal to the axial direction of the first positioning part;

[0017] And / or, the first connecting hole and the magnetic core component are disposed opposite each other in the axial direction of the first positioning part;

[0018] And / or, there is a gap between the first connection hole and the output terminal of the power module, and the gap between the first connection hole and the output terminal of the power module is less than a first threshold.

[0019] And / or, the first connecting hole is a strip hole.

[0020] The motor controller of this invention includes the magnetic core assembly as described in any of the above embodiments.

[0021] In some embodiments, the motor controller further includes a housing and a power module, the output terminal of the power module passing through the first connection hole of the magnetic core assembly, the magnetic core assembly and the power module being movable relative to the housing in a first direction to be fitted onto the housing;

[0022] One of the magnetic core assembly and the power module is positioned with the housing in the first direction before the other.

[0023] In some embodiments, the power module has a second positioning part, the housing has a third positioning part and a fourth positioning part, the first positioning part is connected to the third positioning part, the second positioning part is connected to the fourth positioning part, and the first positioning part, the second positioning part, the third positioning part and the fourth positioning part all have positioning segments;

[0024] The distance between the end of the positioning segment in the first positioning part that is away from the magnetic core assembly and the end of the positioning segment in the third positioning part that is away from the housing is L1, and the distance between the end of the positioning segment in the second positioning part that is away from the power module and the end of the positioning segment in the fourth positioning part that is away from the housing is L2. L1 and L2 satisfy: L1 < L2.

[0025] In the motor controller of this invention, the first connection hole of the magnetic core assembly is directly connected to the power module, allowing for simultaneous assembly during assembly and reducing assembly steps. Furthermore, the positioning structures between the magnetic core assembly and the housing, and between the power module and the housing, are designed to ensure that the initial engagement times of the positioning segments of the first and third positioning parts, and the second and fourth positioning parts, are staggered during assembly, preventing over-positioning during simultaneous assembly.

[0026] In some embodiments, the first positioning hole has a first positioning segment and a first guide segment, wherein the distance between the end of the first guide segment away from the first positioning segment and the end of the first positioning pin is L3, and L3 ≥ L2; or

[0027] It also includes a first connector, the first positioning part being a first positioning hole, the third positioning part being a first positioning pin, the first positioning pin having a second connecting hole, and the magnetic core assembly and the housing being connected by the first connector disposed in the first positioning hole and the second connecting hole; or

[0028] It also includes a second connector, the power module is provided with a third connection hole, and the housing is provided with a fourth connection hole corresponding to the third connection hole. The power module and the housing are connected by the second connector provided in the third connection hole and the fourth connection hole.

[0029] The electric drive system of this invention includes a motor controller as described in any of the above embodiments.

[0030] The vehicle of this invention includes a magnetic core assembly as described in any of the foregoing embodiments, or a motor controller as described in any of the foregoing embodiments, or an electric drive system as described in any of the foregoing embodiments. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the magnetic core assembly according to an embodiment of the present invention.

[0032] Figure 2 This is a schematic diagram of the connection structure between the magnetic core assembly and the power module in an embodiment of the present invention.

[0033] Figure 3This is a schematic diagram showing the disassembled structure of the magnetic core assembly, power module, and housing according to an embodiment of the present invention.

[0034] Figure 4 This is a schematic diagram of the structure of the magnetic core assembly and power module after being assembled with the housing according to an embodiment of the present invention.

[0035] Figure 5 This is a structural schematic diagram showing the relative positions of each positioning part after the magnetic core assembly, power module, and housing are assembled in place according to an embodiment of the present invention.

[0036] Figure 6 This is a structural schematic diagram of the power module and the housing during precise positioning according to an embodiment of the present invention.

[0037] Figure 7 This is a schematic diagram of the positioning structure of the magnetic core assembly during the precise positioning of the power module and the housing in an embodiment of the present invention.

[0038] Figure 8 This is a schematic diagram of the structure of the magnetic core assembly and the housing during precise positioning according to an embodiment of the present invention.

[0039] Figure 9 This is a schematic diagram of the assembly of the magnetic core assembly, power module, and housing in an embodiment of the present invention.

[0040] Figure label:

[0041] 1. Magnetic core assembly;

[0042] 11. Body; 111. First positioning part; 1111. First positioning section; 1112. First guide section; 112. First connecting hole;

[0043] 12. Magnetic core components;

[0044] 13. Bushing; 131. First set body; 132. Boss;

[0045] 14. First connecting component;

[0046] 2. Shell;

[0047] 21. Third positioning part; 211. Second connecting hole;

[0048] 22. Fourth Positioning Section;

[0049] 3. Power module;

[0050] 31. Second positioning section;

[0051] 32. Second connector. Detailed Implementation

[0052] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings. 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.

[0053] like Figure 1 and Figure 2 As shown, the magnetic core assembly 1 according to an embodiment of the present invention includes a body 11 and a magnetic core component 12. The body 11 has a first positioning part 111 and a first connecting hole 112. The magnetic core component 12 is connected to the body 11, and the magnetic core component 12 is arranged correspondingly to the first connecting hole 112. The first connecting hole is used for plugging and connecting to the output end of the power module.

[0054] Specifically, the magnetic core component 12 is a magnetic core that gathers magnetic field lines. The output end of the power module 3 can be a UVW three-phase output connector. The UVW three-phase output connector passes through the first connection hole 112. The magnetic core component 12 converts the electrical signals of the UVW three-phase output connector into magnetic signals respectively. There is no need to set copper busbars in the body 11, nor is it necessary to electrically connect the copper busbars to the UVW three-phase output connector, which reduces the volume of components and lowers production costs.

[0055] The concentrated magnetic field lines can convert the current signal on the UVW three-phase output connector into a magnetic signal. The magnetic signal passes through the Hall element, and due to the Hall effect, the magnetic signal is converted into a voltage signal. The magnitude of the voltage can reflect the magnitude of the current on the UVW three-phase output connector.

[0056] Furthermore, during the assembly of the magnetic core component 12, it can be connected to the power module 3 and assembled together, which improves the assembly efficiency.

[0057] The magnetic core assembly 1 of this invention provides a first connection hole 112 in the body 11, which is used to connect to the output end of the power module 3. The magnetic core component 12 is directly connected to the first connection hole 112. The body 11 no longer has a copper busbar, so there is no need to connect the copper busbar to the output end of the power module 3 electrically. It is also no longer necessary to detect the current on the copper busbar to reflect the current at the output end of the power module 3. This reduces the size of the component and eliminates the need for electrical connection between the copper busbar and the output end of the power module 3, thus saving production costs.

[0058] Furthermore, the extension direction of the first connecting hole is orthogonal to the assembly direction of the magnetic core assembly 1 on the motor controller housing 2.

[0059] like Figure 5 As shown, in some embodiments, the first positioning part 111 is a positioning hole.

[0060] Specifically, the positioning hole has positioning sections and guide sections arranged sequentially along its assembly direction, and the cross-sectional size of the guide section gradually increases from the end closer to the positioning section to the end farther away from the positioning section.

[0061] The assembly direction is from the upper right to the lower right as shown in the figure. By setting the first positioning part 111 as a positioning hole, the positioning hole can be positioned with the positioning pin on the housing 2 of the motor controller during assembly. During the positioning process, the guide section is used for guidance, and the positioning section is used to complete the positioning after being inserted with the positioning pin. During assembly, the positioning pin first matches and aligns with the guide section to complete the coarse positioning, and then inserts with the positioning section to complete the fine positioning, thereby improving the assembly efficiency.

[0062] When the power module 3 and the magnetic core assembly 1 are assembled together, and the power module 3 and the housing 2 of the motor controller are initially positioned, the positioning pin on the housing 2 can be engaged with the guide section on the magnetic core assembly 1 to avoid over-positioning between the power module 3 and the housing 2, and between the magnetic core assembly 1 and the housing 2. In other words, when the positioning pin on the housing 2 engages with the positioning section of the magnetic core assembly 1, the power module 3 and the housing 2 of the motor controller have already been positioned. At the same time, it also ensures that when the power module 3 and the housing 2 are finely positioned, the housing 2 and the magnetic core assembly 1 are coarsely positioned, which facilitates further positioning and assembly of the magnetic core assembly 1 and the housing 2, and enables the simultaneous assembly of the power module 3 and the magnetic core assembly 1. The specific assembly structure is described in further detail below.

[0063] The magnetic core assembly 1 also includes a bushing 13, which is connected to the body 11 and is coaxially arranged with the positioning hole. The bushing 13 is located at one end of the positioning hole. The bushing 13 is used to improve the structural strength of local positions of the body 11. The bushing 13 can be made of metal or other materials with higher hardness and better wear resistance. In this embodiment of the invention, the bushing 13 is coaxially arranged with the positioning hole. After the magnetic core assembly 1 is positioned, the connector passes through the through hole in the middle of the bushing 13 and connects to the housing 2 of the motor controller. By arranging the connector with the positioning hole and the bushing, the connection between the magnetic core assembly 1 and the housing 2 is completed using the connector. There is no need to plan the position of a new connection hole on the body 11, which further reduces the size and volume of the magnetic core assembly to a certain extent, improves the compactness of the structure, and improves the structural strength of the connection area.

[0064] Furthermore, the bushing 13 includes a first body 131 and a boss 132. The boss 132 is connected to the outer wall surface of the first body 131 and is embedded in the body 11.

[0065] The first body 131 is a hollow cylinder. A boss 132 is provided on the outer wall surface of the first body 131 and protrudes from the outer wall surface of the first body 131. The boss 132 can be an annular boss, or multiple bosses can be distributed at intervals on the outer wall surface of the first body 131.

[0066] The boss 132 is embedded in the body 11 to prevent the bushing 13 from falling off the body 11 due to force after the magnetic core assembly 11 and the housing 2 are connected together, thereby improving the structural stability between the bushing 13 and the body 11.

[0067] In some embodiments, the body 11 is an injection molded part. It should be understood that the body 11 is injection molded from injection molding material. During the injection molding process, the magnetic core component 12 and the bushing 13 will be connected to the body 11 as the injection molding material solidifies. At the same time, after injection molding, the first positioning part 111 and the first connecting hole 112 can also be formed simultaneously, avoiding subsequent reprocessing and improving the structural stability and production efficiency of the magnetic core assembly 1.

[0068] In some embodiments, there are multiple first positioning parts 111, first connecting holes 112, and magnetic core components 12. The body 11 has a length direction, and the multiple first positioning parts 111 are arranged at intervals along the length direction of the body 11. The multiple first connecting holes 112 are also arranged at intervals along the length direction of the body 11. The magnetic core components 12 are correspondingly arranged with the first connecting holes 112. The multiple first connecting holes 112 correspond to multiple output connectors in the power module. The arrangement of the multiple first positioning parts 111 can effectively position them with the housing 2 during assembly, and after positioning, the magnetic core assembly can be fixed to the housing 2 by the connector, improving stability.

[0069] For example, there are two first positioning parts 111. The two first positioning parts 111 can ensure the structural stability after the magnetic core assembly 1 is connected to the housing 2 of the motor controller, and avoid relative swinging between the magnetic core assembly 1 and the housing 2. There are three first connection holes 112, which correspond to the UVW three-phase output connectors respectively. There are also three magnetic core components 12, which are respectively set to correspond to the first connection holes 112. The current signals on the UVW three-phase output connectors are detected by the three magnetic core components 12 respectively.

[0070] The length direction of the main body 11 is the left-right direction shown in the figure.

[0071] In some embodiments, the extending direction of the first connecting hole 112 is orthogonal to the axial direction of the first positioning part 111.

[0072] The extension direction of the first connecting hole 112 is also the assembly direction of the power module 3 and the magnetic core assembly 1, that is... Figure 1The front-back direction, the axial direction of the first positioning part 111 is also the assembly direction of the magnetic core assembly 1 and the power module 3 with the housing, that is... Figure 1 As shown in the up and down directions, the assembly direction of the magnetic core assembly 1 and the power module 3 in this embodiment of the invention, as well as the assembly direction of the magnetic core assembly 1 and the power module 3 with the housing, are orthogonal.

[0073] The three components, magnetic core assembly 1, power module 3, and housing 2, are aligned and assembled in two directions in different assembly processes. After the magnetic core assembly 1 and power module 3 are assembled, the magnetic core assembly 1 can be relatively stably supported on the output end of the power module 3, which can prevent the magnetic core assembly 1 and power module 3 from shifting. This facilitates subsequent alignment and assembly with housing 2, and improves the stability and efficiency of the assembly.

[0074] Furthermore, the first connecting hole 112 and the magnetic core component 12 are arranged opposite to each other in the axial direction of the first positioning part 111.

[0075] By arranging the magnetic core component 12 and the first connecting hole 112 opposite to each other in the axial direction of the first positioning part 111, the structure of the magnetic core assembly 1 can be made more compact, which facilitates the miniaturization design of the magnetic core assembly 1. The magnetic core component 12, the first connecting hole 112 and the first positioning part 111 are arranged more compactly on the body 11. When there are multiple first connecting holes 112, magnetic core components 12 and first positioning parts 111, it is convenient to arrange them and improves space utilization, thereby reducing the volume of the magnetic core assembly 1.

[0076] Furthermore, there is a gap between the first connection hole 112 and the output terminal of the power module 3, and the gap between the first connection hole 112 and the output terminal of the power module 3 is less than the first threshold.

[0077] After the first connecting hole 112 and the power module 3 are assembled, there is a certain gap between them. On the one hand, it is convenient to insert the output end of the power module 3 into the first connecting hole 112 to realize the pre-assembly and coarse positioning of the two. On the other hand, by limiting the size of the gap, it is avoided that if the gap is greater than the first threshold, the magnetic core assembly 1 and the power module 3 will have a large displacement and the offset size will be too large, making it impossible to position the magnetic core assembly 1 and the power module 3 when they are assembled with the housing 2.

[0078] When the magnetic core assembly 1 and the power module 3 are assembled onto the housing 2, the relative positions between the magnetic core assembly 1 and the power module 3 can also be finely adjusted under the action of the first positioning part 111 to ensure that the two are accurately positioned with the housing 2 in sequence, thus ensuring a smooth assembly process.

[0079] Optionally, the first threshold can be 1mm, 1.2mm, 1.45mm, 2mm, 3mm or 5mm, etc.

[0080] Furthermore, the first connecting hole 112 is a strip-shaped hole. For example, the cross-section of the first connecting hole 112 is rectangular, or for another example, the first connecting hole 112 is an oblong hole.

[0081] When the first connecting hole 112 is a strip-shaped hole, the size of one side wall of the first connecting hole 112 can be relatively large. Correspondingly, the output end of the power module 3 can be set as a flat plate. When the output end of the power module 3 is inserted into the first connecting hole 112, it is convenient for the magnetic core component 12 to detect the output end of the power module 3.

[0082] like Figures 3-9 As shown, the motor controller of this embodiment includes the magnetic core assembly 1 as described in any of the above embodiments. The beneficial effects obtained by the motor controller are the same as those obtained by the magnetic core assembly in the above embodiments, so they will not be described again.

[0083] In some embodiments, the motor controller further includes a housing 2 and a power module 3. The output end of the power module 3 passes through the first connection hole 112 of the magnetic core assembly 1. The magnetic core assembly 1 and the power module 3 move relative to the housing 2 in a first direction to be assembled onto the housing 2. One of the magnetic core assembly 1 and the power module 3 is positioned with the housing 2 in the first direction before the other.

[0084] In other words, before the power module 3 and the magnetic core assembly 1 are assembled into the housing 2, the power module 3 and the magnetic core assembly 1 are pre-assembled. That is, after the output end of the power module 3 is inserted into the first connection hole 112 of the magnetic core assembly 1, the power module 3 and the magnetic core assembly 1 are pre-assembled. Then, they are assembled into the housing 2. During the assembly process of the power module 3 and the magnetic core assembly 1 into the housing 2, the power module 3 and the magnetic core assembly 1 move closer to the housing 2 in the first direction. One of them is positioned with the housing 2 first. As the power module 3 and the magnetic core assembly 1 move closer to the housing 2 in the first direction, the other is positioned with the housing 2. This avoids the situation where the power module 3 and the magnetic core assembly 1 are simultaneously positioned with the housing 2 and over-positioning occurs.

[0085] Furthermore, in this embodiment of the invention, the power module 3 has a second positioning part 32, and the housing 2 has a third positioning part 21 and a fourth positioning part 22. The first positioning part 111 is connected to the third positioning part 21, and the second positioning part 32 is connected to the fourth positioning part 22. The first positioning part 111, the second positioning part 32, the third positioning part, and the fourth positioning part 22 all have positioning segments. It should be understood that when the positioning segment of the first positioning part 111 and the positioning segment of the third positioning part 21 are connected, the magnetic core assembly 1 can no longer be circumferentially adjusted relative to the housing 2, and can only move along the first direction. Similarly, when the positioning segment of the second positioning part 32 and the positioning segment of the fourth positioning part 22 are connected, the power module 3 can no longer be circumferentially adjusted relative to the housing 2, and can only move along the first direction.

[0086] The first direction is the up-down direction shown in the figure.

[0087] The distance between the end of the positioning segment in the first positioning part 111 that is away from the magnetic core assembly 1 and the end of the positioning segment in the third positioning part 21 that is away from the housing 2 is L1. The distance between the end of the positioning segment in the second positioning part 32 that is away from the power module 3 and the end of the positioning segment in the fourth positioning part 22 that is away from the housing 2 is L2. L1 and L2 satisfy: L1 < L2.

[0088] It should be understood that the dimensions of L1 and L2 mentioned above are the dimensions after the magnetic core assembly 1 and the power module 3 are assembled on the housing 2. Through the dimensional constraints of L1 and L2, during the assembly process, the initial engagement time of the positioning segments of the first positioning part 111 and the third positioning part 21 is staggered from the initial engagement time of the positioning segments of the second positioning part 32 and the fourth positioning part 22. This avoids the magnetic core assembly 1 and the power module 3 being positioned simultaneously with the housing 2, preventing over-positioning. Figure 5 The box M contains the positioning structure of the first positioning part 111 and the third positioning part 21, and the box N contains the positioning structure of the second positioning part 32 and the fourth positioning part 22.

[0089] When L2 > L1, the core assembly 1 and the power module 3 are simultaneously separated from the housing 2. The positioning segment of the first positioning part 111 in the core assembly 1 first separates from the positioning segment of the third positioning part 21 on the housing 2. As the power module 3 and the core assembly 1 move further, the positioning segment of the second positioning part 32 in the power module 3 then separates from the positioning segment of the fourth positioning part 22 on the housing 2. Conversely, during assembly, the power module 3 first completes precise positioning with the housing 2. Figure 6 and Figure 7 As shown, as the power module 3 and the magnetic core assembly 1 move closer to the housing 2, the magnetic core assembly 1 is then precisely positioned with the housing 2, as... Figure 8 As shown.

[0090] In the motor controller of this embodiment, the first connection hole 112 of the magnetic core assembly 1 is directly connected to the power module 3, allowing for simultaneous assembly during assembly and reducing assembly steps. Furthermore, the positioning structures between the magnetic core assembly 1 and the housing 2, and between the power module 3 and the housing 2, are designed to ensure that the initial engagement time of the positioning segments of the first positioning part 111 and the third positioning part 21, and the initial engagement time of the positioning segments of the second positioning part 32 and the fourth positioning part 22, are staggered during assembly, preventing over-positioning during simultaneous assembly.

[0091] like Figures 5-8 As shown, in some embodiments, one of the first positioning part 111 and the third positioning part 21 is a first positioning hole and the other is a first positioning pin; one of the second positioning part 32 and the fourth positioning part 22 is a second positioning hole and the other is a second positioning pin.

[0092] In other words, when the first positioning part 111 in the magnetic core assembly 1 is the first positioning hole, the third positioning part 21 on the housing 2 is the first positioning pin; when the first positioning part 111 in the magnetic core assembly 1 is the first positioning pin, the third positioning part 21 on the housing 2 is the first positioning hole; when the second positioning part 32 in the power module 3 is the second positioning hole, the fourth positioning part 22 on the housing 2 is the second positioning pin; when the second positioning part 32 in the power module 3 is the second positioning pin, the fourth positioning part 22 on the housing 2 is the second positioning hole.

[0093] Furthermore, at least one of the first positioning hole, the first positioning pin, the second positioning hole, and the second positioning pin has a guide section.

[0094] It should be understood that the guide section facilitates the positioning of the locating pin and the locating hole. The guide section on the locating hole or the locating pin is located at the end of its locating section. The guide sections in the locating hole and the locating pin are both tapered. The difference between the guide section in the locating hole and the guide section in the locating pin is that the cross-sectional dimension of the guide section in the locating hole gradually increases from the end closer to the locating section in the locating hole to the end farther away from the locating section in the locating hole; while the cross-sectional dimension of the guide section in the locating pin gradually decreases from the end closer to the locating section in the locating pin to the end farther away from the locating section in the locating pin.

[0095] For example, the first positioning hole has a guide section. During the assembly process, the guide section of the first positioning hole and the first positioning pin can first complete the coarse positioning and then complete the fine positioning.

[0096] For example, the second locating pin has a guide section. During the assembly process, the guide section of the second locating hole and the second locating pin can first complete the coarse positioning and then complete the fine positioning.

[0097] For example, the first positioning hole, the first positioning pin, the second positioning hole, and the second positioning pin all have guide sections.

[0098] like Figures 5-8 As shown, the first positioning part 111 is a first positioning hole, the second positioning part 32 is a second positioning pin, the third positioning part 21 is a first positioning pin, and the fourth positioning part 22 is a second positioning hole. Furthermore, Figure 6 In the diagram, A represents the length of the positioning segment of the second positioning pin in the first direction, and B represents the length of the positioning segment of the second positioning hole in the first direction. Figure 7 In the diagram, C represents the length of the first positioning hole in the first direction, D represents the length of the positioning segment of the first positioning hole in the first direction, and E represents the length of the guide segment of the first positioning hole in the first direction.

[0099] like Figure 7 As shown, in some embodiments, the first positioning hole has a first positioning section 1111 and a first guide section 1112. The cross-sectional size of the first guide section 1112 gradually increases from the end near the first positioning section 1111 to the end away from the first positioning section 1111. The distance between the end of the first guide section 1112 away from the first positioning section 1111 and the end of the first positioning pin is L3, and L3≥L2.

[0100] It should be understood that the size of L3 is also the size after the magnetic core assembly 1 and the power module 3 are assembled on the housing 2. The positioning segment of the second positioning part 32 in the power module 3 first cooperates with the positioning segment of the fourth positioning part 22 on the housing 2. The embodiment of the present invention constrains the size of L3. When the positioning segment of the second positioning part 32 and the positioning segment of the fourth positioning part 22 have initially completed fine positioning, the first guide segment 1112 of the first positioning hole and the first positioning pin can be matched, thereby simultaneously completing the coarse positioning of the housing 2 and the magnetic core assembly 1. Then, as the magnetic core assembly 1 and the power module 3 move further toward the housing 2, the magnetic core assembly 1 and the housing 2 can be assembled through the fine positioning of the first positioning hole and the first positioning pin.

[0101] Taking L1 < L2, and the first positioning part 111 as the first positioning hole, the second positioning part 32 as the second positioning pin, the third positioning part 21 as the first positioning pin, and the fourth positioning part 22 as the second positioning hole, with the first positioning hole having a first positioning section 1111 and a first guide section 1112 as an example, the assembly process can be divided into the following steps in the specific operation:

[0102] ① The magnetic core assembly 1 and the power module 3 are fully engaged, and the grippers ensure that there is no relative movement between the magnetic core assembly 1 and the power module 3. Figure 2 As shown.

[0103] ② The gripper-controlled magnetic core assembly 1 is assembled together with the power module 3, and moves towards the housing 2 of the motor controller, as shown. Figure 3 As shown, when the positioning segment of the second positioning pin of the power module 3 begins to enter the positioning segment of the second positioning hole on the housing 2, fine positioning is completed between the power module 3 and the housing 2, and the gripper stops at this time. When the gripper stops, coarse positioning is completed between the magnetic core assembly 1 and the housing 2, that is, the first positioning pin on the housing 2 enters the first guide segment 1112 of the first positioning hole on the magnetic core assembly 1, but does not enter the first positioning segment 1111 of the first positioning hole on the magnetic core assembly 1, and does not interfere with the magnetic core assembly 1, as shown. Figure 6 and Figure 7 As shown.

[0104] like Figure 7 The diagram shows the state when the power module 3 and housing 2 have just completed fine positioning and the magnetic core assembly 1 has completed coarse positioning. d1 is the distance from the end face of the second positioning pin to the end face of the first positioning hole; d2 is the distance from the end face of the second positioning pin to the end of the first positioning segment 1111 in the first positioning hole near the first guide segment 1112; d3 is the distance from the end face of the second positioning pin to the starting end of the positioning segment of the first positioning pin (the end of the positioning segment that mates with the first positioning hole during assembly). Considering the dimensional tolerances of the parts and the tolerances introduced during assembly, d1, d2, and d3 each have a maximum and a minimum value. When the power module 3 and housing 2 have completed fine positioning and the magnetic core assembly 1 has completed coarse positioning, the following condition is met: d 2min ≥d 3max And d 3min ≥d 1max At this point, the first locating pin does not include the guide section.

[0105] Furthermore, when the first locating pin has a guide section, then d4 is the distance from the end face of the second locating pin to the starting end of the guide section of the first locating pin (the end of the guide section that mates with the first locating hole during assembly), which satisfies: d 2min ≥d 3max And d 4min ≥d 1max .

[0106] ③ The grippers release. Since the power module 3 and the housing 2 have already completed precise positioning, the power module 3 continues to fall after the grippers release, completing the installation. Simultaneously, after the grippers release, since the core assembly 1 and the housing 2 have only completed coarse positioning, through the cooperation between the first positioning pin on the housing 2 and the first guide section 1112 of the first positioning hole on the core assembly 1, and the action of gravity, the positioning section of the first positioning pin enters the first positioning section 1111 of the first positioning hole, achieving precise positioning between the core assembly 1 and the housing 2. Figure 8 As shown, and as the magnetic core assembly 1 is further lowered, the installation of the magnetic core assembly 1 is completed. The magnetic core assembly 1 is then fastened to the power module 3 using screws and other connectors, thus completing the assembly. Figure 9 As shown.

[0107] In some embodiments, the motor controller further includes a first connector 14, a first positioning part 111 being a first positioning hole, a third positioning part 21 being a first positioning pin, and a second connecting hole 211 on the first positioning pin. The magnetic core assembly 1 and the housing 2 are connected by the first connector 14 provided in the first positioning hole and the second connecting hole 211.

[0108] In other words, the magnetic core assembly 1 and the housing 2 can be connected and fixed by the first connecting member 14 through the structure of the first positioning part 111 and the third positioning part 21. After the magnetic core assembly 1 and the housing 2 are positioned and assembled, they are connected and fixed by the first connecting member 14.

[0109] The first connector 14 can be a bolt or screw, and the second connecting hole 211 is a threaded hole. A bushing 13 can be arranged on the body 11 of the magnetic core assembly 1 to improve the structural strength between the first connector 14 and the body 11. The first connector 14 passes through the through hole of the bushing 13 and is threadedly connected to the second connecting hole 211.

[0110] By using the first connector 14 with the first positioning part 111 and the third positioning part 21, the first connector 14 does not need to occupy a new area on the body 11, which can further reduce the size of the magnetic core assembly 1, improve the overall compactness of the magnetic core assembly, and increase the power density of the motor controller.

[0111] In some embodiments, the motor controller further includes a second connector 32, the power module 3 is provided with a third connection hole, and the housing 2 is provided with a fourth connection hole corresponding to the third connection hole. The power module 3 and the housing 2 are connected by the second connector 32 provided in the third connection hole and the fourth connection hole.

[0112] In other words, the second connecting member 32 is not provided between the power module 3 and the housing 2 without the structural support of the second positioning part 31 and the fourth positioning part 22. This is because the power module 3 has a relatively large structural size, is a key component with higher requirements for structural stability, and there is sufficient space between the power module 3 and the housing 2 to arrange the second connecting member 32. Therefore, a third connecting hole is provided on the power module 3 and a fourth connecting hole is provided on the housing 2. The connection and fixation of the power module 3 and the housing 2 are completed by the second connecting member 32 provided in the corresponding third and fourth connecting holes. This allows for a more reasonable planning of the position of the second connecting member 32, thereby ensuring the structural stability between the power module 3 and the housing 2.

[0113] Optionally, the second connector 32 can be a bolt or a screw.

[0114] The electric drive system of this invention includes a motor controller as described in any of the above embodiments.

[0115] The vehicle of this invention includes a magnetic core assembly 1 as in any of the above embodiments, a motor controller as in any of the above embodiments, or an electric drive system as in any of the above embodiments.

[0116] The vehicle can be an electric vehicle, specifically a pure electric vehicle, a range-extended electric vehicle, or other hybrid electric vehicle.

[0117] The beneficial effects achieved by the vehicle in this embodiment of the invention are at least partially the same as or similar to the beneficial effects achieved by the magnetic core assembly 1 or the motor controller in the above embodiments, and therefore will not be described again.

[0118] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0119] 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 at least one 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.

[0120] 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, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0121] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0122] In this invention, the terms "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which 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. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0123] 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 magnetic core assembly, characterized in that, include: The body has a first positioning part and a first connecting hole; A magnetic core component is connected to the body and is arranged corresponding to the first connection hole, which is used to plug into the output terminal of the power module.

2. The magnetic core assembly according to claim 1, characterized in that, The first positioning part is a positioning hole, and the magnetic core assembly also includes a bushing. The bushing is connected to the body, and the bushing and the positioning hole are coaxially arranged. The bushing is located at one end of the positioning hole.

3. The magnetic core assembly according to claim 2, characterized in that, The positioning hole has positioning sections and guide sections arranged sequentially along its assembly direction, and the cross-sectional size of the guide section gradually increases from the end closer to the positioning section to the end farther away from the positioning section.

4. The magnetic core assembly according to claim 2, characterized in that, The bushing includes a first body and a boss, the boss being connected to the outer wall surface of the first body and embedded in the body.

5. The magnetic core assembly according to any one of claims 1-4, characterized in that, The extending direction of the first connecting hole is orthogonal to the axial direction of the first positioning part; And / or, the first connecting hole and the magnetic core component are disposed opposite each other in the axial direction of the first positioning part; And / or, there is a gap between the first connection hole and the output terminal of the power module, and the gap between the first connection hole and the output terminal of the power module is less than a first threshold. And / or, the first connecting hole is a strip hole.

6. A motor controller, characterized in that, Includes the magnetic core assembly as described in any one of claims 1 to 5.

7. The motor controller according to claim 6, characterized in that, It also includes a housing and a power module, the output end of which passes through the first connection hole of the magnetic core assembly, and the magnetic core assembly and the power module are movable relative to the housing in a first direction to be assembled onto the housing; One of the magnetic core assembly and the power module is positioned with the housing in the first direction before the other.

8. The motor controller according to claim 7, characterized in that, The power module has a second positioning part, and the housing has a third positioning part and a fourth positioning part. The first positioning part is connected to the third positioning part, and the second positioning part is connected to the fourth positioning part. The first positioning part, the second positioning part, the third positioning part, and the fourth positioning part all have positioning segments. The distance between the end of the positioning segment in the first positioning part that is away from the magnetic core assembly and the end of the positioning segment in the third positioning part that is away from the housing is L1, and the distance between the end of the positioning segment in the second positioning part that is away from the power module and the end of the positioning segment in the fourth positioning part that is away from the housing is L2. L1 and L2 satisfy: L1 < L2.

9. The motor controller according to claim 8, characterized in that, The first positioning hole has a first positioning section and a first guide section. The cross-sectional dimension of the first guide section gradually increases from the end closer to the first positioning section to the end farther away from the first positioning section. The distance between the end of the first guide section farther away from the first positioning section and the end of the first positioning pin is L3, and L3 ≥ L2; or It also includes a first connector, the first positioning part is a first positioning hole, the third positioning part is a first positioning pin, the first positioning pin has a second connecting hole, and the magnetic core assembly and the housing are connected by the first connector provided in the first positioning hole and the second connecting hole; or It also includes a second connector, the power module is provided with a third connection hole, and the housing is provided with a fourth connection hole corresponding to the third connection hole. The power module and the housing are connected by the second connector provided in the third connection hole and the fourth connection hole.

10. An electric drive system comprising a motor controller as claimed in any one of claims 6 to 9.

11. A vehicle, characterized in that, It includes the magnetic core assembly as described in any one of claims 1-5, the motor controller as described in any one of claims 6 to 9, or the electric drive system as described in claim 10.

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