Power distribution integrated device, motor controller, motor assembly, and vehicle

Abstract

The application relates to the technical field of electrical equipment, and provides a power distribution integrated device, a motor controller, a motor assembly and a vehicle. In the power distribution integrated device, a first type of power distribution device for realizing a first type of power distribution function and a second type of power distribution device for realizing a second type of power distribution function are arranged. The power distribution integrated device has an insulation cavity for accommodating an insulator so that the insulator can cover the first type of power distribution device, and the second type of power distribution device is used to define the insulation cavity. Through the technical scheme, the second type of power distribution device for realizing the power distribution function in the power distribution integrated device is used to define the insulation cavity, additional components are not needed, the setting space of the power distribution device is left out, and the flexibility of the layout of the motor controller is improved.

Description

Technical Field

[0001] This application relates to the field of electrical equipment technology, and in particular to a power distribution integrated device, a motor controller, a motor assembly, and a vehicle. Background Technology

[0002] Currently, some electrical devices (such as motor controllers) are usually composed of multiple components that work together to achieve various functions of the device. In order to ensure the normal operation of each component, the corresponding components are potted with glue to achieve the effect of insulation. Insulation can prevent the components from overheating and posing a fire risk, and can also improve the stability of the components.

[0003] In related technologies, in order to accommodate potting compound, ribs are usually provided on the shell to form a cavity for accommodating the potting compound.

[0004] However, this method of forming the potting cavity limits the flexibility of the layout between the various components. Summary of the Invention

[0005] This application provides a power distribution integrated device that improves the layout flexibility of the power distribution integrated device, thereby at least partially solving the above-mentioned technical problems.

[0006] To achieve the above objectives, according to a first aspect of this application, a power distribution integrated device is provided, comprising:

[0007] Class I power distribution devices, used to realize Class I power distribution functions; and

[0008] The second type of power distribution device is used to realize the second type of power distribution function;

[0009] The power distribution integration device has an insulating cavity for accommodating an insulator so that the insulator can cover the first type of power distribution device, and the second type of power distribution device is used to define the insulating cavity.

[0010] Optionally, the first type of power distribution device includes one of: a power switch, a capacitor, a current filter, and an AC filter;

[0011] The second type of power distribution devices includes one or more of the following: power switches, capacitors, DC filters, and AC filters, which are different from the first type of power distribution devices.

[0012] Optionally, the power distribution integration device further includes:

[0013] A shell, having an internal space;

[0014] The first type of power distribution device and the second type of power distribution device are located in the internal space of the housing;

[0015] The housing and the second type of power distribution device together define the insulating cavity.

[0016] Optionally, the second type of power distribution device includes:

[0017] A first power distribution device is used to define a first boundary of the insulating cavity;

[0018] A second power distribution device is used to define a second boundary of the insulating cavity;

[0019] A third power distribution device is used to define a third boundary of the insulating cavity;

[0020] The housing includes:

[0021] A retaining wall is used to define the fourth boundary of the insulating cavity;

[0022] The first power distribution device, the second power distribution device, the third power distribution device, and the retaining wall together define the insulating cavity.

[0023] Optionally, the power switch includes:

[0024] The first type of connection terminal is connected to the capacitor;

[0025] The capacitor includes:

[0026] The second type of connection terminal is connected to the power switch;

[0027] The first type of connection terminal and the second type of connection terminal are laser welded to make the power switch electrically connected to the capacitor.

[0028] Optionally, different first-type connection terminals are spaced apart in a first direction.

[0029] Optionally, the capacitor further includes:

[0030] A connector is used to provide a connection part;

[0031] The first grounding terminal is connected to the connecting part of the connector;

[0032] The power distribution integration device also includes:

[0033] Circuit boards are used to drive and control power distribution devices;

[0034] The circuit board includes:

[0035] The second grounding terminal is connected to the first grounding terminal;

[0036] The first grounding terminal is combined with the second grounding terminal to ground the circuit board through the capacitor.

[0037] Optionally, the power switch further includes:

[0038] The third type of connection terminal is used for connection to the AC filter;

[0039] The AC filter includes:

[0040] The fourth type of connection terminal is used for connection to the third type of connection terminal and the first type of wiring harness terminal of the motor, respectively; and

[0041] The first type of magnetic ring is located between the third type of connection terminal and the fourth type of connection terminal;

[0042] The fourth type of connection terminal is located between the third type of connection terminal and the first type of wire harness terminal. The first type of magnetic ring has a through space for the first type of wire harness terminal to pass through, so that the first type of wire harness terminal passes through the through space and combines with the fourth type of connection terminal.

[0043] Optionally, the first type of magnetic ring includes a three-phase nanocrystalline magnetic ring.

[0044] Optionally, the AC filter further includes:

[0045] The first type of switch is used to control the on / off state of the fourth type of connection terminal and the first type of wire harness terminal;

[0046] The first type of switch is connected to the fourth type of connection terminal which is different from the first type of switch.

[0047] Optionally, the AC filter further includes:

[0048] The second type of switch is used to cut off the electric arc generated by the fourth type of connection terminal;

[0049] The second type of switch is connected to the fourth type of connection terminal, bypassing the first type of switch.

[0050] Optionally, the capacitor further includes:

[0051] The fifth type of connection terminal is used for connection to the DC filter;

[0052] The DC filter includes:

[0053] The sixth type of connection terminal is used to connect the fifth type of connection terminal of the capacitor and the second type of wiring harness terminal of the power battery.

[0054] Optionally, the DC filter further includes:

[0055] The first-stage filter capacitor is connected between the sixth type of connection terminal and the second type of wiring harness terminal of the power battery;

[0056] The second-stage filter capacitor is connected between the first-stage filter capacitor and the sixth type of connection terminal;

[0057] Among them, the different first-stage filter capacitors are spaced apart along the first direction, and the different second-stage filter capacitors are spaced apart along the second direction.

[0058] The first direction and the second direction are set perpendicularly or intersecting.

[0059] Optionally, on a projection plane perpendicular to the first direction, the projection of the first-stage filter capacitor is staggered from the projection of the second-stage filter capacitor; and / or

[0060] On the projection plane perpendicular to the second direction, the projection of the first-stage filter capacitor is offset from the projection of the second-stage filter capacitor.

[0061] Optionally, the DC filter further includes:

[0062] The seventh type of connection terminal is used to connect the second type of wiring harness terminal and the sixth type of connection terminal of the power battery;

[0063] The second type of magnetic ring is located between the seventh type of connection terminal and the second type of wire harness terminal;

[0064] The second type of magnetic ring has a through space for the second type of wire harness terminal to pass through, so that the second type of wire harness terminal passes through the through space and combines with the seventh type of connection terminal.

[0065] Optionally, the second type of magnetic ring includes a first magnetic ring and a second magnetic ring stacked along a second direction;

[0066] The first magnetic ring includes a nanocrystalline magnetic ring, and the second magnetic ring includes a ferrite magnetic ring.

[0067] Optionally, the sixth type of connection terminal includes:

[0068] The first connection terminal is used to supply direct current to the positive terminal of the power battery;

[0069] The second connection terminal is used to supply the negative DC power of the power battery;

[0070] The seventh type of connection terminal includes:

[0071] The third connection terminal is used to connect to the positive terminal of the power battery bus.

[0072] The fourth connection terminal is used to connect to the negative terminal of the power battery bus.

[0073] Wherein, the first connection terminal and the third connection terminal are connected through a DC positive input conductor, and the second connection terminal and the fourth connection terminal are connected through a DC negative input conductor;

[0074] On a projection plane perpendicular to the first direction, the projections of the DC positive input conductor and the DC negative input conductor are arranged to overlap.

[0075] Optionally, the power distribution integration device further includes:

[0076] Circuit boards are used to drive and control power distribution devices; and

[0077] A heat exchange plate is used for heat exchange with the circuit board;

[0078] The heat exchange plate is located between the circuit board and the housing.

[0079] Optionally, the housing includes:

[0080] A base for forming the internal space of the shell; and

[0081] The top cover is used to seal the internal space of the shell;

[0082] The heat exchange plate is located between the circuit board and the upper cover.

[0083] Optionally, the top cover has a recess that is recessed into the surface of the top cover in a third direction;

[0084] The recessed portion is in contact with the surface of the heat exchange plate.

[0085] According to a second aspect of this application, a motor controller is provided, including a power distribution integrated device as described above.

[0086] According to a third aspect of this application, a motor assembly is provided, including a power distribution integration device as described above or a motor controller as described above.

[0087] According to a fourth aspect of this application, a vehicle is provided, including a power distribution integration device as described above, a motor controller as described above, or a motor assembly as described above.

[0088] The beneficial effect of this application is that it provides a motor controller that improves the layout flexibility of power distribution integrated devices.

[0089] More specifically, some embodiments of this application may produce the following specific beneficial effects:

[0090] The power distribution integration device of this application includes a first type of power distribution device that implements a first type of power distribution function and a second type of power distribution device that implements a second type of power distribution function. The power distribution integration device of this application has an insulating cavity for accommodating an insulator so that the insulator can cover the first type of power distribution device, and the insulating cavity is defined by the second type of power distribution device. Through the above technical solution, by using the second type of power distribution device in the power distribution integration device to define the insulating cavity, no additional components need to be added, which frees up space for the power distribution device and improves the flexibility of the motor controller layout.

[0091] Other features and advantages of this application will be described in detail in the following detailed description section. Attached Figure Description

[0092] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0093] To gain a more complete understanding of this application and its beneficial effects, the following description will be provided in conjunction with the accompanying drawings, wherein the same reference numerals in the following description denote the same parts.

[0094] Figure 1 This is a schematic diagram of the overall structure of the power distribution integrated device provided in an exemplary embodiment of this application;

[0095] Figure 2 This is a schematic diagram of the boundary of the insulating cavity formed by the power distribution integrated device provided in an exemplary embodiment of this application;

[0096] Figure 3 This is an exploded structural diagram of the power distribution integration device provided in an exemplary embodiment of this application;

[0097] Figure 4 This is a schematic diagram of the structure of the housing provided in an exemplary embodiment of this application;

[0098] Figure 5 This is a schematic diagram of the structure of the capacitor provided in an exemplary embodiment of this application;

[0099] Figure 6 This is a schematic diagram of the structure of the AC filter provided in an exemplary embodiment of this application;

[0100] Figure 7 yes Figure 6 A schematic diagram of the AC filter from another angle;

[0101] Figure 8 This is a schematic diagram of an AC filter with another structure provided in an exemplary embodiment of this application;

[0102] Figure 9 This is a schematic diagram of the structure of a DC filter provided in an exemplary embodiment of this application;

[0103] Figure 10 This is a schematic diagram of the DC filter provided in an exemplary embodiment of this application from another angle;

[0104] Figure 11 This is an exploded structural diagram of the heat-conducting plate between the top cover and the circuit board provided in an exemplary embodiment of this application;

[0105] Figure 12 This is a schematic diagram of the power switch provided in an exemplary embodiment of this application;

[0106] Figure 13 This is a schematic diagram of the overall structure of the vehicle provided in an exemplary embodiment of this application;

[0107] Explanation of reference numerals in the attached figures:

[0108] 10. Integrated power distribution equipment;

[0109] 100. Class I power distribution devices;

[0110] 200. Class II power distribution devices;

[0111] 10a, Insulating cavity; 10a1, First boundary; 10a2, Second boundary; 10a3, Third boundary;

[0112] 10a4, Fourth Boundary; 10a41, First Sub-Boundary; 10a42, Second Sub-Boundary;

[0113] 300, shell; 300a, internal space of the shell;

[0114] 310, retaining wall; 3110, first sub-retaining wall; 3120, second sub-retaining wall;

[0115] 320. Base;

[0116] 330. Upper cover; 331. Recess;

[0117] 340. Inlet pipe; 350. Outlet pipe;

[0118] 1. Capacitor;

[0119] 11. Type II connection terminal; 12. Connector; 13. First grounding terminal; 14. Plastic retaining wall; 15. Type V connection terminal;

[0120] 2. AC filter;

[0121] 21. Category IV connection terminal; 22. Category I magnetic ring; 23. Category I switch; 24. Category II switch; 25. Glue-blocking rib; 26. Category VIII connection terminal;

[0122] 3. DC filter;

[0123] 31. Category 6 connection terminal; 311. First connection terminal; 312. Second connection terminal;

[0124] 32. First-stage filter capacitor; 33. Second-stage filter capacitor; 34. Outer wall;

[0125] 35. Second type of magnetic ring; 351. First type of magnetic ring; 352. Second type of magnetic ring;

[0126] 36. Class III switches;

[0127] 37. Category 7 connector; 371. Third connector; 372. Fourth connector;

[0128] 4. Power switch;

[0129] 41. Type I connection terminal; 42. Type III connection terminal;

[0130] 5. DC positive input conductor;

[0131] 6. DC negative input conductor;

[0132] 61. First DC negative input conductor; 62. Second DC negative input conductor;

[0133] 7. Heat exchange plate; 8. Circuit board;

[0134] A. Vehicles. Detailed Implementation

[0135] The technical solutions of the embodiments of this application 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 this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the protection scope of this application.

[0136] Reference Figures 1 to 12 As shown, for ease of explanation, the corresponding figures use the orientations of up, down, left, right, front, and back to illustrate the relative positional relationships between the parts in this application. These should not be construed as limitations on absolute positions.

[0137] Furthermore, in this application, the first direction corresponds to the front-back direction, the second direction corresponds to the left-right direction, and the third direction corresponds to the up-down direction. Similarly, the first direction here indicates the front-back direction only for the convenience of introducing the specific embodiments of this application. There is no absolute correspondence between the first direction and the front-back direction. Likewise, there is no absolute correspondence between the second direction and the left-right direction, and between the third direction and the up-down direction.

[0138] The first, second, and third directions in this application are only for expressing relative positional relationships; they merely indicate approximate locations rather than absolute geometric relationships.

[0139] According to the first aspect of this application, reference to Figures 1 to 12 A power distribution integrated device 10 is provided, including a first type of power distribution device 100 that realizes a first type of power distribution function and a second type of power distribution device 200 that realizes a second type of power distribution function.

[0140] The power distribution integrated device 10 has an insulating cavity 10a for accommodating an insulator so that the insulator can cover the first type of power distribution device 100, and a second type of power distribution device 200 for defining the insulating cavity 10a.

[0141] By using the above technical solution, the insulating cavity 10a is defined by the second type of power distribution device 200 that realizes the power distribution function in the power distribution integrated device 10. This eliminates the need for additional components, frees up space for the power distribution device, and improves the flexibility of the motor controller layout.

[0142] The power distribution integrated device 10 in this embodiment has good space utilization, can reasonably configure the positional relationship between various devices, improve electrical control safety, avoid device combustion and fire, and the power distribution integrated device 10 can simplify the assembly and installation process and reduce production costs.

[0143] Specifically, the insulator can be potting compound, and the insulating cavity 10a can accommodate the potting compound. That is, the potting compound spreads within the insulating cavity 10a to the boundary of the insulating cavity 10a. The second type of power distribution device 200 can limit the insulating compound within the insulating cavity 10a to achieve the effect of covering the first type of power distribution device 100.

[0144] In some embodiments, the first type of power distribution device 100 includes one of a power switch 4, a capacitor 1, a DC filter, and an AC filter 2, and the second type of power distribution device 200 includes one or more of the power switch 4, capacitor 1, DC filter 3, and AC filter 2 that are different from the first type of power distribution device 100.

[0145] The first type of power distribution device 100 and the second type of power distribution device 200 are configured differently. When the first type of power distribution device 100 is configured as a power switch 4, the second type of power distribution device 200 is one or more of a capacitor, a DC filter 3, and an AC filter 2.

[0146] Specifically, capacitor 1 is a bus capacitor, which can be a film capacitor or an electrolytic capacitor; AC filter 2 is a three-phase AC filter; and power switch 4 is an IGBT switch or a SiC switch.

[0147] In some embodiments, the power distribution integration device 10 further includes a housing 300.

[0148] The housing 300 of this application has an internal space 300a, in which the first type of power distribution device 100 and the second type of power distribution device 200 are located, and the housing 300 and the second type of power distribution device 200 together define an insulating cavity 10a.

[0149] The insulating cavity 10a is defined by the housing 300 and the second type of power distribution device 200, which further improves the flexibility of the power distribution integrated device 10 in forming the insulating cavity 10a. The insulating cavity 10a can be defined by cooperating with the housing 300 according to the installation position of each power distribution device, thereby improving the integration of the power distribution integrated device 10 and reducing the amount of space 300a occupied by each power distribution device in the housing.

[0150] In some embodiments, the second type of power distribution device 200 includes a first power distribution device, a second power distribution device, and a third power distribution device, and the housing 300 includes a retaining wall.

[0151] The first power distribution device defines a first boundary 10a1 of the insulating cavity 10a, the second power distribution device defines a second boundary 10a2 of the insulating cavity 10a, the third power distribution device defines a third boundary 10a3 of the insulating cavity 10a, and a fourth boundary 10a4 of the insulating cavity 10a is defined by a retaining wall. The first boundary 10a1, the second boundary 10a2, the third boundary 10a3 and the fourth boundary 10a4 enclose the insulating cavity 10a.

[0152] The first power distribution device, the second power distribution device, the third power distribution device, and the retaining wall together define the insulating cavity 10a.

[0153] This arrangement makes full use of the arrangement relationship between the second type of power distribution device 200 and the retaining wall of the housing 300, further improving the compactness of the power distribution integrated device 10, thereby increasing the integration degree of the power distribution integrated device 10 and reducing the fire risk of the product.

[0154] Specifically, the first power distribution device can be a thin-film capacitor, the second power distribution device can be a DC filter 3, and the third power distribution device can be a three-phase AC filter 2.

[0155] refer to Figure 4 The retaining wall 310 of the housing 300 includes a first retaining wall and a second retaining wall. The first retaining wall 310 includes a first sub-retaining wall 3110 and a second sub-retaining wall 3120 that are continuously arranged. The projections of the first sub-retaining wall 3110 and the second sub-retaining wall 3120 in a projection plane perpendicular to the first direction are staggered. The first sub-retaining wall 3110 is used to define the first sub-boundary 10a41 of the fourth boundary 10a4 of the insulating cavity 10a.

[0156] Meanwhile, the second barrier wall is set relative to the first sub-barrier wall 3110. In the projection plane perpendicular to the first direction, the projections of the second barrier wall and the first sub-barrier wall 3110 partially overlap. The second barrier wall is used to define the second sub-boundary 10a42 of the fourth boundary 10a4 of the insulating cavity 10a.

[0157] It should be noted that the second barrier wall can be formed by the wall of the shell 300, and the first barrier wall is a plate located in the inner space, which forms the first barrier wall.

[0158] Similarly, the first power distribution device (i.e., the film capacitor) has plastic barriers 14 extending along a first direction and a second direction to form a first boundary 10a1 of the insulating cavity 10a.

[0159] The second power distribution device (i.e., DC filter 3) has an outer wall 34 extending along a second direction. Along the second direction, the outer wall 34 is located between the first sub-barrier 3110 and the plastic barrier 14, and is used to define the second boundary 10a2 of the insulating cavity 10a. The two opposite ends of the outer wall 34 abut against the plastic barrier 14 and the first sub-barrier 3110 respectively, so that the first boundary 10a1, the second boundary 10a2 and the first sub-boundary 10a41 are continuously arranged, thereby enabling the insulation to extend out of the insulating cavity 10a.

[0160] Similarly, the third power distribution device (i.e., the three-phase AC filter 2) has a baffle plate 25 extending along the first direction. This baffle plate 25 is located between the first sub-baffle wall 3110 and the second baffle wall along the first direction, which can define the third boundary 10a3 of the insulating cavity 10a. The opposite ends of this baffle plate 25 abut against the first sub-baffle wall 3110 and the second baffle wall, so that the first sub-boundary 10a41, the third boundary 10a3 and the second sub-boundary 10a42 are continuously arranged, thereby also limiting the insulator to extend out of the insulating cavity 10a.

[0161] The opposite ends of the plastic retaining wall 14 of this application abut against the two opposite inner wall surfaces inside the shell.

[0162] The insulation cavity 10a is confined by the aforementioned capacitor, DC filter 3, three-phase AC filter 2, and the retaining wall of the housing 300, resulting in a reasonable structural layout.

[0163] In some embodiments, the power switch 4 includes a first type of connection terminal 41, and the capacitor 1 includes a second type of connection terminal 11.

[0164] The capacitor and the power switch 4 are electrically connected through the first type of connection terminal 41 and the second type of connection terminal 11.

[0165] The first type of connection terminal 41 and the second type of connection terminal 11 are laser welded to make the power switch 4 electrically connected to the capacitor.

[0166] By using laser welding to combine the first type of connection terminal 41 and the second type of connection terminal 11, laser welding not only improves assembly efficiency but also reduces stray inductance, thereby improving the efficiency and system stability of the motor controller equipped with the power distribution integrated device 10.

[0167] Specifically, the first type of connection terminal 41 includes positive and negative copper busbars connected to the capacitor, and the second type of connection terminal 11 includes the positive AC terminal and the negative AC terminal of the capacitor respectively connected to the positive and negative copper busbars of the power switch 4.

[0168] In some embodiments, different first-type connection terminals 41 are spaced apart in a first direction, thereby ensuring a stable connection between the first-type connection terminals 41 and the second-type connection terminals 11 of the capacitor.

[0169] In some embodiments, capacitor 1 further includes a connector 12 and a first connection terminal 311, and power distribution integration device 10 further includes a circuit board 8 for driving and controlling power distribution devices.

[0170] The connector 12 is used to provide a connection portion for connecting the first grounding terminal 13 to the connection portion of the connector 12.

[0171] The circuit board 8 includes a second ground terminal, which is connected to the first ground terminal 13.

[0172] The first grounding terminal 13 is combined with the second grounding terminal to ground the circuit board 8 through a capacitor.

[0173] By setting up a circuit board 8 that can drive and control the power distribution device, this circuit board 8 is an integrated circuit board 8. The connector 12 is a fixing nut, the first grounding terminal 13 is a grounding copper busbar, and the second grounding terminal is also a grounding copper busbar. By connecting the two grounding copper busbars, the circuit board 8 is grounded through a capacitor. This method satisfies the grounding requirements of the circuit board 8 and can also fix the circuit board 8, which can reduce the space occupied by the capacitor and the circuit board 8 to a certain extent.

[0174] In some embodiments, capacitor 1 further includes a positive terminal and a negative terminal of a high-voltage sampling needle. The positive terminal and the negative terminal of the high-voltage sampling needle are connected to circuit board 8 by soldering for high-voltage sampling, which reduces wiring harness connections and can improve manufacturing efficiency.

[0175] The positive and negative terminals of the high-voltage sampling needle are located on the upper surface of the capacitor.

[0176] In some embodiments, the power switch 4 further includes a third type of connection terminal 42, and the AC filter 2 includes a fourth type of connection terminal 21 and a first type of magnetic ring 22.

[0177] The third type of connection terminal 42 can be connected to the AC filter 2, and the fourth type of connection terminal 21 can be connected to the third type of connection terminal 42 and the first type of wiring harness terminal of the motor respectively. The first type of magnetic ring 22 is placed between the third type of connection terminal 42 and the fourth type of connection terminal 21.

[0178] The fourth type of connection terminal 21 is located between the third type of connection terminal 42 and the first type of wire harness terminal. The first type of magnetic ring 22 has a through space for the first type of wire harness terminal to pass through, so that the first type of wire harness terminal passes through the through space and combines with the fourth type of connection terminal 21.

[0179] By providing a through space in the first type of magnetic ring 22 for the first type of wire harness terminal to pass through, the first type of wire harness terminal can pass through the through space and combine with the fourth type of connection terminal 21.

[0180] Specifically, the first type of magnetic ring 22 is a three-phase nanocrystalline magnetic ring, which can effectively suppress common-mode interference current, reduce the interference propagation between the motor controller and the motor, thereby reducing the EMI emission level of the entire power distribution integrated device 10 and reducing the interference level in the AM band. Furthermore, the nanocrystalline material has high permeability and wide bandwidth characteristics, and can provide high impedance in the high-frequency range, thereby effectively filtering out high-frequency interference.

[0181] It should be noted that the fourth type of connection terminal 21 of the AC filter 2 includes the three-phase copper busbar U phase, V phase and W phase, and the first type of wiring harness terminal of the motor includes the terminals of the three-phase motor wires. The terminals of the three-phase motor wires pass through the three-phase nanocrystalline magnetic ring and are fixed to the three-phase copper busbar with bolts.

[0182] In some embodiments, the AC filter 2 further includes an eighth type connection terminal 26.

[0183] The eighth type of connection terminal 26 is located between the third type of connection terminal 42 of the power switch 4 and the fourth type of connection terminal 21 of the AC filter 2.

[0184] In some embodiments, the AC filter 2 further includes a first type of switch 23.

[0185] The first type of switch 23 can control the on / off state of the fourth type of connection terminal 21 and the first type of wire harness terminal, wherein the first type of switch 23 is connected to the different fourth type of connection terminal 21.

[0186] By setting a first-type switch 23 between the different fourth-type connection terminals 21, the first-type switch 23 can actively disconnect the V-phase copper bus and the W-phase copper bus, which can prevent the electronic control from being impacted by back electromotive force when problems such as motor stall occur. Back electromotive force is generally greater than the maximum voltage that the electronic control can withstand. Under the action of back electromotive force, the controller module may explode and catch fire, endangering the safety of the entire vehicle. At the same time, it can also be set to transmit signals to the first-type switch 23 through sensors, so that the response is rapid.

[0187] Specifically, the first type of switch 23 includes an active fuse. The use of an active fuse can improve the protection speed and accuracy. It can quickly determine whether to disconnect based on external trigger signals or its own high-voltage system sampling signals. Its response speed is much faster than that of traditional fuses. It can cut off the circuit in a very short time, avoiding serious damage to the system caused by overcurrent or overvoltage. It can also accurately disconnect the circuit when the overcurrent or overvoltage reaches the dangerous value, avoiding unnecessary malfunctions or leakage protection, and protecting critical components.

[0188] In some embodiments, the AC filter 2 further includes a second type of switch 24.

[0189] The second type of switch 24 is used to cut off the electric arc generated by the fourth type of connection terminal 21, wherein the second type of switch 24 bypasses the first type of switch 23 and is connected to the fourth type of connection terminal 21.

[0190] By using the first type of switch 23 to cut off the arc generated by the fourth type of connection terminal 21, an arc-extinguishing function is achieved, ensuring that no fire occurs after the three-phase copper busbar of the AC filter 2 is disconnected, thus ensuring the safety of the electronic control system and the entire vehicle. For example, the second type of switch 24 includes a miniature fuse. When the current in the circuit exceeds the rated current of the fuse, the fuse will quickly melt and cut off the current, preventing damage to components in the circuit due to overcurrent. Furthermore, miniature fuses are low-cost, easy to replace, and can reduce maintenance costs.

[0191] In some embodiments, capacitor 1 further includes a fifth type of connection terminal 15, and DC filter 3 includes a sixth type of connection terminal 31.

[0192] The fifth type of connection terminal 15 can be connected to the DC filter 3, and the sixth type of connection terminal 31 can connect the fifth type of connection terminal 15 of the capacitor and the second type of wiring harness terminal of the power battery, thereby realizing the electrical connection between the DC filter 3 and the capacitor.

[0193] It should also be noted that the outer wall 34 of the DC-AC converter forms the second boundary 10a2. The front side of this outer wall 34 is used to form the second boundary 10a2, while the rear side is used to form a receiving space for accommodating the sixth type of connection terminal 31.

[0194] In some embodiments, the DC filter 3 further includes a first-stage filter capacitor 32 and a second-stage filter capacitor 33.

[0195] The first-stage filter capacitor 32 is connected between the sixth-type connection terminal 31 and the second-type wiring harness terminal of the power battery, and the second-stage filter capacitor 33 is connected between the first-stage filter capacitor 32 and the sixth-type connection terminal 31.

[0196] In this configuration, different first-stage filter capacitors 32 are spaced apart along a first direction, and different second-stage filter capacitors 33 are spaced apart along a second direction, with the first and second directions being perpendicular or intersecting.

[0197] Through the first-stage filter capacitor 32 and the second-stage filter capacitor 33 of the DC filter 3, the two filter capacitors can filter out noise in different frequency ranges respectively. The first-stage filter capacitor 32 may have a better filtering effect on high-frequency noise, while the second-stage filter capacitor 33 can be optimized for mid- and low-frequency noise. In this way, the entire DC filter 3 can cover a wider frequency range and effectively filter out noise of various frequencies.

[0198] Specifically, both the first-stage filter capacitor 32 and the second-stage filter capacitor 33 can be set as safety capacitors.

[0199] In some embodiments, on a projection plane perpendicular to the first direction, the projections of the first-stage filter capacitor 32 and the second-stage filter capacitor 33 are offset from each other, and on a projection plane perpendicular to the second direction, the projections of the first-stage filter capacitor 32 and the second-stage filter capacitor 33 are offset from each other.

[0200] By setting the projection of the first-stage filter capacitor 32 and the projection of the second-stage filter capacitor 33 to be staggered on the projection plane perpendicular to the first direction, and setting the projection of the first-stage filter capacitor 32 and the projection of the second-stage filter capacitor 33 to be staggered on the projection plane perpendicular to the second direction, the DC filter 3 is set in an L-shape, which can further make full use of the space inside the housing 300.

[0201] In some embodiments, the sixth type of connection terminal 31 includes: a first connection terminal 311 and a second connection terminal 312.

[0202] The first connection terminal 311 can supply the positive DC power of the power battery, and the second connection terminal 312 can supply the negative DC power of the power battery.

[0203] Specifically, the second type of wiring harness terminals of the power battery consists of two connection terminals, positive and negative, which are defined as the positive connection terminal and the negative connection terminal of the busbar, respectively. The first connection terminal 311 of the sixth type of connection terminal 31 is connected to the positive connection terminal of the power battery, and the second connection terminal 312 is connected to the negative connection terminal of the power battery.

[0204] In some embodiments, the DC filter 3 further includes a third type of switch 36 disposed between the two ends of the two DC negative input conductors 6, the third type of switch 36 including a DC active safety switch.

[0205] In some embodiments, the DC filter 3 further includes a seventh type connection terminal 37 and a second type magnetic ring 35.

[0206] The seventh type connection terminal 37 is used to connect the second type wiring harness terminal and the sixth type connection terminal 31 of the power battery. The second type magnetic ring 35 is located between the seventh type connection terminal 37 and the second type wiring harness terminal. The second type magnetic ring 35 has a through space for the second type wiring harness terminal to pass through, so that the second type wiring harness terminal passes through the through space and combines with the seventh type connection terminal 37.

[0207] For example, the seventh type of connection terminal 37 includes a third connection terminal 371 and a fourth connection terminal 372 for bus connection of the power battery.

[0208] The third connection terminal 371 is connected to the positive terminal of the busbar and is defined as the positive terminal connection terminal 1407 of the busbar.

[0209] Connect the fourth connection terminal 372 to the negative terminal of the busbar, and define it as the negative terminal connection 1408 of the busbar.

[0210] The sixth type of connection terminal 31 and the seventh type of connection terminal 37 are connected by an input conductor. That is, a DC positive input conductor 5 is provided between the first connection terminal 311 and the third connection terminal 371. The second connection terminal 312 and the fourth connection terminal 372 are connected by a DC negative input conductor 6. The DC filter 3 includes two DC negative input conductors 6, and the two DC negative input conductors 6 are connected by a third switch.

[0211] In this configuration, the projections of the DC positive input conductor 5 and the DC negative input conductor 6 are overlapped on a projection plane perpendicular to the first direction.

[0212] By overlapping the projections of the DC positive input conductor 5 and the DC negative input conductor 6 on a projection plane perpendicular to the first direction, the narrow space on the capacitor side of the power distribution successor device can be further utilized more rationally. Furthermore, by overlapping the projections of the DC positive input conductor 5 and the DC negative input conductor 6 on a projection plane perpendicular to the first direction, the stacked arrangement of the two connection terminals can be achieved, which can also reduce the stray inductance of the DC copper busbar itself.

[0213] To facilitate a clear description of the positions and connections between the ends, the two DC negative input conductors 6 are defined as the first DC negative input conductor 61 and the second DC negative input conductor 62.

[0214] A capacitor consists of a positive copper busbar and a negative copper busbar.

[0215] refer to Figure 9 and Figure 10 The first connection terminal 311 at one end of the DC positive input conductor 5 is connected to the positive copper busbar of the film capacitor, and the third connection terminal 371 at the other end is connected to the positive busbar of the power battery.

[0216] The second connection terminal 312 at one end of the first DC negative input conductor 61 is the capacitor negative connection terminal connected to the capacitor negative copper busbar of the film capacitor, and the fourth connection terminal 372 at the other end is the active fuse connection terminal connected to the DC active fuse switch.

[0217] One end of the second DC negative input conductor 62 is a DC active fuse connection terminal connected to the other end of the DC active fuse switch, and the fourth connection terminal at the other end of the second DC negative input conductor 62 is a bus negative connection terminal connected to the negative terminal of the power battery bus.

[0218] In cases of motor stall or abnormal battery output, it is necessary to actively disconnect the external input to ensure electronic control safety. In this case, the control board can transmit a control signal to the DC active fuse to actively disconnect the connection between the negative copper busbar of the DC input, thus ensuring the safety of the electronic control system and the entire vehicle.

[0219] Specifically, the DC active fuse switch can be arranged horizontally between the two fuse connection terminals, which can make better use of this space and reduce the space occupied by the filter.

[0220] In some embodiments, the second type of magnetic ring 35 includes a first magnetic ring 351 and a second magnetic ring 352 stacked along a second direction, wherein the first magnetic ring 351 includes a nanocrystalline magnetic ring and the second magnetic ring 352 includes a ferrite magnetic ring.

[0221] By setting two magnetic rings, impedance can be provided in different frequency ranges, which is equivalent to setting two "barriers" in the power distribution integrated device 10, so that interference signals are doubly blocked and attenuated when passing through, and the filtering depth is significantly enhanced.

[0222] Furthermore, the two types of magnetic rings are nanocrystalline magnetic rings and ferrite magnetic rings. Nanocrystalline magnetic rings mainly function in the low-frequency range, while ferrite magnetic rings perform excellently in the high-frequency range. When used together, they can achieve wide-band interference suppression, covering the entire spectrum from low to high frequencies.

[0223] In some embodiments, the DC filter 3 also has a silicon steel sheet 1402, and the first DC negative input conductor 611412 passes over the silicon steel sheet to facilitate the Hall sensor chip on the drive control circuit board 816 to sense and detect the DC input current.

[0224] The DC filter 3 in this application is a highly integrated filter, which can further make the layout of the power distribution integrated device 10 more reasonable.

[0225] In some embodiments, the power distribution integration device 10 further includes a circuit board 8 and a heat exchange plate 7.

[0226] Circuit board 8 is used to drive and control the power distribution devices, and heat exchange plate 7 is used to exchange heat with the circuit board.

[0227] The heat exchange plate 7 is located between the circuit board 8 and the housing 300.

[0228] By setting a heat exchange plate 7 between the circuit board 8 and the housing 300, heat dissipation of the circuit board 8 is achieved.

[0229] Especially for the position of the bleed resistor 1601 on the circuit board 8, since the high voltage platform requires the bleed to be completed in a very short time, the number of bleed resistors needs to be increased to meet the bleed requirements, which leads to an increase in the volume of the circuit board 8. Therefore, the heat exchange plate 7 is set up to conduct the heat generated by the bleed resistor during the bleed process to the top cover 330 for heat dissipation. This method can improve the utilization rate of the bleed resistor arrangement space and save the installation space of the enclosure.

[0230] In some embodiments, the housing 300 includes a base 320 and a top cover 330.

[0231] The base 320 is used to form the internal space 300a, and the top cover 330 is used to close the internal space 300a.

[0232] The heat exchange plate 7 is located between the circuit board 8 and the upper cover 330.

[0233] In some embodiments, the upper cover 330 has a recess 331 recessed in a third direction on the surface of the upper cover 330; wherein the recess 331 is in contact with the surface of the heat exchange plate 7.

[0234] The upper cover 330 is provided with a recess 331 that is recessed into the surface of the upper cover 330 in a third direction, and the recess 331 is attached to the surface of the heat exchange plate 7 to further improve the heat dissipation effect, such as improving the heat dissipation efficiency.

[0235] In this application, a heat exchange cavity can also be provided inside the base 320. At the same time, the base 320 is connected to an inlet pipe 340 and an outlet pipe 350. Both the inlet pipe 340 and the outlet pipe 350 are connected to the heat exchange cavity. The heat exchange medium flows into and out of the heat exchange cavity through the inlet pipe 340 and the outlet pipe 350 to realize the heat exchange of the power distribution integrated device 10.

[0236] It should be noted that the heat exchange medium can be a refrigerant or a gas. Therefore, the water in the outlet pipe 350 and the inlet pipe 340 is a general term and may not necessarily be water.

[0237] In some embodiments, such as Figure 8 The diagram shows another possible scheme for the three-phase AC filter 2. As can be seen from the diagram, one side of the three-phase AC filter 2 is the motor terminal UVW three-phase connection point connected to the motor, which is also the fourth type of connection terminal 21. The other side is the module terminal UVW three-phase connection point connected to the power switch 4, which is also the eighth type of connection terminal 26. The copper busbar terminals of the active safety switch are connected to the safety connection points on the three-phase AC filter 2. The active safety copper busbar terminal is a single copper busbar connected to the motor terminal. In case of emergency, it can actively disconnect the connection between the U and W phase copper busbars to protect the safety of the electrical control product.

[0238] It should be noted that the second sub-barrier 3120 in this application can isolate the DC filter 3 and the AC filter 2 so that they can be set up independently of each other.

[0239] According to a second aspect of this application, a motor controller is provided, including a power distribution integrated device 10 as described above.

[0240] According to a second aspect of this application, a motor controller is provided, which includes the aforementioned power distribution integrated device 10. The motor controller has all the beneficial effects of the aforementioned power distribution integrated device 10, which will not be repeated here.

[0241] According to a third aspect of this application, a motor assembly is provided, including either the power distribution integration device 10 as described above or the motor controller as described above.

[0242] According to a third aspect of this application, a motor assembly is provided, which includes the aforementioned power distribution integration device 10. The motor assembly has all the beneficial effects of the aforementioned power distribution integration device 10, which will not be repeated here.

[0243] The motor assembly includes the aforementioned motor controller, and the motor assembly has all the beneficial effects of the aforementioned motor controller, which will not be repeated here.

[0244] According to the fourth aspect of this application, with reference to Figure 13 A vehicle A is provided, including the above-described power distribution integration device 10, the above-described motor controller, or the above-described motor assembly.

[0245] According to the fourth aspect of this application, with reference to Figure 13 The present application provides a vehicle A, which includes the aforementioned power distribution integrated device 10. The vehicle A has all the beneficial effects of the aforementioned power distribution integrated device 10, which will not be repeated here.

[0246] The vehicle A includes the aforementioned motor controller, and the vehicle A has all the beneficial effects of the aforementioned motor controller, which will not be repeated here.

[0247] The vehicle A includes the aforementioned motor assembly, and the vehicle A has all the beneficial effects of the aforementioned motor assembly, which will not be repeated here.

[0248] The vehicle A can be a gasoline-powered vehicle, a plug-in hybrid electric vehicle, or a new energy vehicle, etc., and this application does not make any specific restrictions on it.

[0249] In the description of this application, 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. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more features. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0250] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0251] The embodiments, implementation methods, and related technical features of this application can be combined and substituted for each other without conflict.

[0252] The above are merely preferred embodiments of this application and are not intended to limit this application in any way. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of this application without departing from the scope of the technical solution of this application shall still fall within the scope of the technical solution of this application.

Claims

1. A power distribution integrated device (10), characterized in that, The power distribution integrated device (10) includes: The first type of power distribution device (100) is used to realize the first type of power distribution function; and The second type of power distribution device (200) is used to realize the second type of power distribution function; The power distribution integration device (10) has an insulating cavity (10a) for accommodating an insulator so that the insulator can cover the first type of power distribution device (100), and the second type of power distribution device (200) is used to define the insulating cavity (10a).

2. The power distribution integrated device (10) according to claim 1, characterized in that, The first type of power distribution device (100) includes one of the following: power switch (4), capacitor (1), current filter, and AC filter (2); The second type of power distribution device (200) includes one or more of the following that are different from the first type of power distribution device (100): power switch (4), capacitor (1), DC filter (3), and AC filter (2).

3. The power distribution integrated device (10) according to claim 2, characterized in that, The power distribution integration device (10) also includes: A shell (300) having an internal space (300a); The first type of power distribution device (100) and the second type of power distribution device (200) are located in the internal space (300a); The housing (300) and the second type of power distribution device (200) together define the insulating cavity (10a).

4. The power distribution integrated device (10) according to claim 3, characterized in that, The second type of power distribution device (200) includes: A first power distribution device is used to define a first boundary (10a1) of the insulating cavity (10a); A second power distribution device is used to define a second boundary (10a2) of the insulating cavity (10a); A third power distribution device is used to define the third boundary (10a3) of the insulating cavity (10a); The housing (300) includes: A retaining wall (310) is used to define the fourth boundary (10a4) of the insulating cavity (10a); The first power distribution device, the second power distribution device, the third power distribution device, and the retaining wall (310) together define the insulating cavity (10a).

5. The power distribution integrated device (10) according to claim 3, characterized in that, The power switch (4) includes: The first type of connection terminal (41) is connected to the capacitor (1); The capacitor (1) includes: The second type of connection terminal (11) is connected to the power switch (4); The first type of connection terminal (41) and the second type of connection terminal (11) are laser welded to make the power switch (4) electrically connected to the capacitor (1).

6. The power distribution integrated device (10) according to claim 5, characterized in that, Different first-type connection terminals (41) are spaced apart in a first direction.

7. The power distribution integrated device (10) according to claim 5, characterized in that, The capacitor (1) also includes: Connector (12), used to provide a connecting part; The first grounding terminal (13) is connected to the connecting part of the connector (12); The power distribution integration device (10) also includes: Circuit board (8) is used to drive and control the power distribution devices; The circuit board (8) includes: The second grounding terminal is connected to the first grounding terminal (13); The first grounding terminal (13) is combined with the second grounding terminal to ground the circuit board (8) through the capacitor (1).

8. The power distribution integrated device (10) according to claim 2, characterized in that, The power switch (4) also includes: The third type of connection terminal (42) is used to connect to the AC filter (2); The AC filter (2) includes: The fourth type of connection terminal (21) is used for connection to the third type of connection terminal (42) and the first type of wiring harness terminal of the motor, respectively; and The first type of magnetic ring (22) is located between the third type of connecting terminal (42) and the fourth type of connecting terminal (21); The fourth type of connection terminal (21) is located between the third type of connection terminal (42) and the first type of wire harness terminal. The first type of magnetic ring (22) has a through space for the first type of wire harness terminal to pass through, so that the first type of wire harness terminal passes through the through space and combines with the fourth type of connection terminal (21).

9. The power distribution integrated device (10) according to claim 8, characterized in that, The first type of magnetic ring (22) includes a three-phase nanocrystalline magnetic ring.

10. The power distribution integrated device (10) according to claim 8, characterized in that, The AC filter (2) also includes: The first type of switch (23) is used to control the on / off state of the fourth type of connection terminal (21) and the first type of wire harness terminal; Among them, the first type of switch (23) is connected to the fourth type of connection terminal (21) which is different.

11. The power distribution integrated device (10) according to claim 10, characterized in that, The AC filter (2) also includes: The second type of switch (24) is used to cut off the electric arc generated by the fourth type of connection terminal (21); The second type of switch (24) bypasses the first type of switch (23) and is connected to the fourth type of connection terminal (21).

12. The power distribution integrated device (10) according to claim 2, characterized in that, The capacitor (1) also includes: The fifth type of connection terminal (15) is used to connect to the DC filter (3); The DC filter (3) includes: The sixth type of connection terminal (31) is used to connect the fifth type of connection terminal (15) of the capacitor (1) and the second type of wiring harness terminal of the power battery.

13. The power distribution integrated device (10) according to claim 12, characterized in that, The DC filter (3) also includes: The first-stage filter capacitor (32) is connected between the sixth type of connection terminal (31) and the second type of wiring harness terminal of the power battery; The second-stage filter capacitor (33) is connected between the first-stage filter capacitor (32) and the sixth type of connection terminal (31); Among them, the different first-stage filter capacitors (32) are spaced apart along the first direction, and the different second-stage filter capacitors (33) are spaced apart along the second direction; The first direction and the second direction are set perpendicularly or intersecting.

14. The power distribution integrated device (10) according to claim 13, characterized in that, On a projection plane perpendicular to the first direction, the projection of the first-stage filter capacitor (32) is offset from the projection of the second-stage filter capacitor (33); and / or On the projection plane perpendicular to the second direction, the projection of the first-stage filter capacitor (32) is offset from the projection of the second-stage filter capacitor (33).

15. The power distribution integrated device (10) according to claim 13, characterized in that, The DC filter (3) also includes: The seventh type of connection terminal (37) is used to connect the second type of wiring harness terminal and the sixth type of connection terminal (31) of the power battery; The second type of magnetic ring (35) is located between the seventh type of connection terminal (37) and the second type of wire harness terminal; The second type of magnetic ring (35) has a through space for the second type of wire harness terminal to pass through, so that the second type of wire harness terminal passes through the through space and combines with the seventh type of connection terminal (37).

16. The power distribution integrated device (10) according to claim 15, characterized in that, The second type of magnetic ring (35) includes a first magnetic ring (351) and a second magnetic ring (352) stacked along a second direction; The first magnetic ring (351) includes a nanocrystalline magnetic ring, and the second magnetic ring (352) includes a ferrite magnetic ring.

17. The power distribution integrated device (10) according to claim 15, characterized in that, The sixth type of connection terminal (31) includes: The first connection terminal (311) is used to supply the positive DC power of the power battery; The second connection terminal (312) is used to supply the negative DC power of the power battery; The seventh type of connection terminal (37) includes: The third connection terminal (371) is used to connect to the positive terminal of the power battery bus. The fourth connection terminal (372) is used to connect to the negative terminal of the power battery bus; The first connection terminal (311) and the third connection terminal (371) are connected through a DC positive input conductor (5), and the second connection terminal (312) and the fourth connection terminal (372) are connected through a DC negative input conductor (6). On a projection plane perpendicular to the first direction, the projections of the DC positive input conductor (5) and the DC negative input conductor (6) are arranged to overlap.

18. The power distribution integrated device (10) according to claim 3, characterized in that, The power distribution integration device (10) also includes: Circuit board (8) is used to drive and control the power distribution devices; and Heat exchange plate (7) is used for heat exchange with the circuit board; The heat exchange plate (7) is located between the circuit board (8) and the housing (300).

19. The power distribution integrated device (10) according to claim 18, characterized in that, The housing (300) includes: A base (320) for forming the internal space (300a) of the shell; and The top cover (330) is used to close the internal space (300a) of the shell; The heat exchange plate (7) is located between the circuit board (8) and the upper cover (330).

20. The power distribution integrated device (10) according to claim 19, characterized in that, The upper cover (330) has a recess (331) recessed into the surface of the upper cover (330) in a third direction; The recess (331) is in contact with the surface of the heat exchange plate (7).

21. A motor controller, characterized in that, Includes the power distribution integrated device (10) as described in any one of claims 1 to 20.

22. A motor assembly, characterized in that, This includes the power distribution integrated device (10) as described in any one of claims 1 to 20 or the motor controller as described in claim 21.

23. A vehicle, characterized in that, This includes the power distribution integrated device (10) as described in any one of claims 1 to 20, the motor controller as described in claim 21, or the motor assembly as described in claim 22.

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