Motor controller assembly, electric drive assembly and hybrid power assembly

Abstract

This invention belongs to the field of hybrid power technology, specifically relating to a motor controller assembly, an electric drive assembly, and a hybrid powertrain. The motor controller assembly includes: a controller base plate; a cold plate assembly mounted on the controller base plate; a power module assembly comprising several power modules distributed and mounted on the upper and lower surfaces of the cold plate assembly, forming an upper power module group and a lower power module group; and a capacitor assembly mounted sideways on the controller base plate, located in front of the cold plate assembly and the power module assembly, and electrically connected to each power module via a DC bus assembly. This invention combines a double-layer arrangement of power modules with a side-mounted capacitor assembly, further reducing the footprint of the motor and freeing up installation space. It can be used to arrange generator controllers, DC / DC controllers, or other electric drive controller modules, enabling the motor, motor controller assembly, and other controllers to form an integrated structure.

Description

Technical Field

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

[0002] Currently, in the design architecture of hybrid power systems, the electric motor and its controller are typically arranged separately, requiring high-current three-phase power cables, aviation connectors, and various terminal blocks for electrical connection. This traditional connection method not only significantly extends the power transmission path from the motor to the controller, introducing large stray inductance and putting significant pressure on the system's electromagnetic compatibility performance, but also reduces long-term reliability because the connection points and wiring harnesses are constantly exposed to vibration, shock, and alternating thermal cycles near the engine, further increasing the system's size and weight. Furthermore, the typically compact space inside the engine compartment makes it difficult to effectively stack multiple controller modules within this area, further limiting the improvement of system integration.

[0003] To address these challenges, there is an urgent need to develop a highly integrated design scheme for hybrid power systems, achieving an integrated structural layout of the motor and controller. This scheme aims to optimize electrical performance and reliability by shortening the power loop and reducing intermediate connection links through compact integration. At the same time, the integrated design can further free up space below and around the motor, creating favorable conditions for arranging more control modules or other key components, ultimately improving the space utilization efficiency and integration level of the entire power system. Summary of the Invention

[0004] The present invention addresses the above-mentioned technical problems by providing a motor controller assembly, an electric drive assembly, and a hybrid power assembly.

[0005] A motor controller assembly, the motor controller assembly comprising:

[0006] Controller base plate;

[0007] A cold plate assembly is disposed on the controller base plate;

[0008] A power module assembly, comprising a plurality of power modules, wherein the plurality of power modules are distributed and mounted on the upper and lower surfaces of the cold plate assembly along the thickness direction of the cold plate assembly, thereby forming an upper power module group and a lower power module group on the upper and lower surfaces of the cold plate assembly, respectively, wherein the upper power module group and the lower power module group form a thermally conductive fit with the cold plate assembly.

[0009] A capacitor assembly is mounted sideways on the controller base plate to reduce the footprint of the capacitor assembly on the controller base plate. The capacitor assembly is located in front of the cold plate assembly and the power module assembly. The capacitor assembly is electrically connected to each of the power modules through a DC bus assembly.

[0010] Optionally, the upper and lower surfaces of the cold plate assembly are respectively provided with a plurality of opening slots for connecting the power modules, and the interior of the cold plate assembly is respectively provided with an upper cooling cavity and a lower cooling cavity communicating with the opening slots on the same side. The upper cooling cavity is the heat exchange area of ​​the upper power module group, and the lower cooling cavity is the heat exchange area of ​​the lower power module group.

[0011] Optionally, the cooling circuits of the upper cooling chamber and the lower cooling chamber are parallel flow-dividing circuits and / or series circuits.

[0012] Optionally, the edge of the opening groove is provided with a sealing groove and / or a sealing device, and the power module is sealed to the opening groove.

[0013] Optionally, the power module assembly further includes:

[0014] A plurality of AC busbars, each of the AC busbars being electrically connected to an AC terminal of a corresponding power module;

[0015] A plurality of current sensors, wherein the current sensors are used to detect the phase current and / or the branch current of the power module;

[0016] A driver board assembly, wherein the driver board assembly is electrically connected to a plurality of the power modules;

[0017] Each of the power modules is respectively provided with a set of AC busbars and a current sensor, thereby forming a power module unit, and the power module assembly includes a plurality of the power module units.

[0018] Optionally, the current sensor is disposed on the connection path between the AC terminal of the power module and the AC busbar and / or with the external three-phase connector.

[0019] Optionally, the DC bus assembly includes a positive DC bus and a negative DC bus, and an insulating layer is sandwiched between the positive DC bus and the negative DC bus to form a stacked bus structure.

[0020] Optionally, the capacitor assembly is fixed to the controller base plate by a bracket, the bracket having a vibration-resistant reinforcement structure and / or a terminal insulation protection structure.

[0021] Optionally, the capacitor assembly is connected to the power bus corresponding to the upper power module group and the power bus corresponding to the lower power module group through the DC bus assembly, thereby providing DC support to both the upper power module group and the lower power module group simultaneously.

[0022] Optionally, the motor controller assembly further includes several three-phase busbars, each of which is electrically connected to the AC side of the power module assembly via an AC busbar.

[0023] Optionally, several of the three-phase busbars are connected to power modules of different heights by means of staggered lengths.

[0024] Optionally, the controller base plate on the front side of the capacitor assembly has a reserved installation area for installing a generator controller and / or a DC / DC controller and / or other electric drive controller modules.

[0025] An electric drive assembly includes a motor and a motor controller assembly for controlling the motor, wherein the motor controller assembly employs the motor controller assembly provided above in this invention;

[0026] The motor controller assembly is installed below or to the side of the motor and forms a longitudinally stacked integrated structure with the motor;

[0027] The three-phase winding terminals of the motor are located at the rear end and / or the upper rear region of the motor. The three-phase winding terminals of the motor are rigidly electrically connected to the AC side of the power module component of the motor controller assembly through several three-phase busbars, thereby shortening the three-phase power circuit and reducing stray inductance.

[0028] Optionally, the motor controller assembly has a mounting area corresponding to the rear end and / or upper rear region of the motor, and the three-phase busbar extends and bends in the axial and / or radial directions within the mounting area to be electrically connected to the corresponding three-phase winding terminals, respectively.

[0029] Optionally, a support structure is provided on the three-phase busbar to improve its mechanical strength under vibration and to ensure the electrical clearance between phases and to ground.

[0030] A hybrid powertrain includes an engine and an electric drive assembly, wherein the electric drive assembly employs the electric drive assembly provided above in this invention.

[0031] Beneficial effects: The present invention has at least one or more of the following advantages:

[0032] 1. The present invention coordinates the double-layer arrangement of the power module with the side-mounted arrangement of the capacitor assembly to further reduce the footprint of the motor and free up the installation area (i.e., the reserved installation area). This reserved installation area can be used to arrange the generator controller, DC / DC controller or other electric drive controller modules, so that the motor, motor controller assembly and other controllers can form an integrated structure.

[0033] 2. The motor controller assembly of the present invention is integrated with the motor via a rigid direct connection using a three-phase busbar. This eliminates the need for connecting cables, flexible cables, and intermediate terminals, offering the following significant advantages:

[0034] (1) The three-phase power circuit is extremely short and the stray inductance is small: the three-phase busbar is almost a direct connection from terminal to terminal, and the loop is extremely small, which is conducive to suppressing voltage spikes and oscillations under SiC high-frequency switching and is EMC friendly.

[0035] (2) Reduce high-current connectors and cables: Eliminate aviation connectors and long cables, reduce contact resistance and heat generation, and reduce contact failure points in vibration environment; reduce the resistance loss that may be generated in intermediate connection links, so that the power transmission efficiency is significantly improved, thereby improving the overall working efficiency of the motor. Under the same working conditions, it can output stronger power and meet more high-load and high-performance working needs.

[0036] (3) Highly integrated structure: The whole machine has changed from "motor + cable + controller" to "motor + controller vertical integrated module", which is convenient to be arranged as a standardized unit around the engine, making the entire electrical connection path clearer and more intuitive, greatly reducing the probability of failure caused by complex connection, and improving the stability and reliability of system operation;

[0037] (4) Maintenance and upkeep bring great convenience: When maintenance personnel conduct daily inspections and troubleshooting, they can locate the problem more quickly and accurately without having to search for the fault point among a large number of complicated cables and connectors. This greatly shortens the maintenance time, reduces maintenance costs, improves the maintainability of the equipment, and provides a strong guarantee for the long-term stable operation of the equipment.

[0038] 3. In this invention, several power modules and capacitor components of the motor controller assembly are arranged along the length of the controller base plate, that is, in the left-right direction perpendicular to the motor axis. The controller base plate is located below the motor, so that the entire motor controller assembly is located in the middle area below the motor, which has the following significant advantages:

[0039] (1) Small longitudinal dimensions, compact in the middle, and empty on both sides: The power module and capacitor assembly are arranged side by side in the left and right directions, and occupy very little space in the front and back directions, so that the "thickness" of the motor controller assembly is concentrated directly below the motor, and the upper left and right sides are naturally left empty as reserved installation space, which can be used to arrange other ECUs such as engine controller, starter / generator controller, etc.

[0040] (2) Provide a regular “landing edge” for the three-phase busbar: The three-phase output installation area is concentrated on the side near the motor. This edge is exactly the “landing point” of the three-phase busbar hanging down from the motor above. The three-phase busbar can be arranged in sequence in a plane and neatly connected to the three-phase output end of the power module.

[0041] (3) Convenient modular design and assembly: The power module, capacitor assembly and drive board assembly are all arranged around the same controller base plate. The motor controller assembly can be pre-installed as an independent module and then connected to the motor above.

[0042] 4. In the motor controller assembly of the present invention, the capacitor assembly and the power module are arranged front and rear, and are directly electrically connected through the DC bus assembly. This has the advantages of low DC bus inductance, compact loop, short path, and small area, which helps to reduce bus peak voltage and losses. In addition, the power module of the present invention is located at the rear, and there is a mounting area behind it. The AC terminals of the power module are uniformly arranged in the mounting area and then connected to the three-phase bus, so that the power module has a unified "external interface". The internal wiring of the motor controller assembly is neat, the external interface is clear, and it is convenient to connect with the generator above.

[0043] 5. This invention integrates the cold plate assembly into the motor controller assembly. The power module assemblies are uniformly mounted on the upper and lower surfaces of the cold plate assembly. The cold plate assembly is fixed to the controller base plate and bears mechanical loads and vibrations together with the controller base plate. A liquid cooling medium, preferably an existing working fluid in a hybrid power system (such as fuel), is circulated inside the cold plate assembly. The cold plate assembly, controller base plate, and three-phase busbar form a mutually supporting integrated frame, which has the following significant advantages:

[0044] (1) Reliable heat dissipation under high power density: The power module (SiC module) generates concentrated heat under high switching frequency and high power conditions. The junction temperature can be effectively controlled by the cold plate assembly, thereby improving the power density and lifespan.

[0045] (2) Using existing media, the system is simple: using fuel (or the working medium already in the system) as the cooling medium, there is no need to set up a new cooling circuit, reducing system complexity and additional mass;

[0046] (3) The integrated thermo-mechanical-electric structure improves vibration resistance and reliability: The cold plate assembly itself is a rigid component, which forms a closed mechanical circuit with the controller base plate, three-phase busbar and motor housing. The transmission path of vibration from the engine, motor housing, three-phase busbar and cold plate assembly to the controller base plate is clear. Through the integrated structural design, relative displacement can be controlled, reducing electrical connection fatigue and mechanical damage.

[0047] (4) The upper and lower cooling chambers correspond to the heat exchange areas of the upper and lower power modules, respectively, supporting higher power density and improving temperature uniformity.

[0048] Furthermore, the cold plate is not merely a standalone "heat dissipation component," but also a "load-bearing platform":

[0049] (1) The lower end of the three-phase busbar is fixed to the AC terminal of the power module. The power module is mounted on the cold plate assembly, and the cold plate assembly is mounted on the controller base plate. The relative position of the terminals is stable during thermal expansion and contraction and vibration through the rigid support of the cold plate assembly and the controller base plate.

[0050] (2) The length direction of the power module assembly and the length direction of the cold plate assembly are both arranged in a direction that is horizontal and perpendicular to the motor axis. The power modules are concentrated near the cold plate assembly, which is conducive to the efficient operation of the cold plate assembly.

[0051] (3) The compact front-to-back arrangement of capacitor components and power module components reduces the need for dispersed arrangement of power devices, making "centralized cooling of cold plate + overall support" possible.

[0052] 6. The present invention provides a support structure on the three-phase busbar for positioning support, so as to improve the mechanical strength under vibration environment and ensure the electrical clearance between phases and to ground. Attached Figure Description

[0053] Figure 1 This is a schematic diagram of a structure according to Embodiment 1 of the present invention;

[0054] Figure 2 for Figure 1 Another perspective illustration;

[0055] Figure 3 for Figure 1 Partial exploded view;

[0056] Figure 4 This is a partial internal schematic diagram of the controller housing in Embodiment 1 of the present invention;

[0057] Figure 5 for Figure 4 Another angle of the diagram;

[0058] Figure 6This is a diagram showing the positional relationship between the motor controller assembly and the controller base plate in Embodiment 1 of the present invention;

[0059] Figure 7 for Figure 6 Exploded view;

[0060] Figure 8 for Figure 6 Partial structural diagram;

[0061] Figure 9 This is a schematic diagram of a fuel line in Embodiment 1 of the present invention;

[0062] Figure 10 This is a schematic diagram of the fuel circuit in Embodiment 1 of the present invention;

[0063] Figure 11 This is a schematic diagram of a lubricating oil circuit in Embodiment 1 of the present invention;

[0064] Figure 12 This is a schematic diagram of the lubricating oil circuit in Embodiment 1 of the present invention;

[0065] Figure 13 This is a schematic diagram of a controller housing structure excluding the controller base plate in Embodiment 1 of the present invention;

[0066] Figure 14 A schematic diagram of the structure of a single power module unit in Embodiment 1 of the present invention;

[0067] Figure 15 This is a simulation diagram of the cold plate being cooled by fuel oil in Embodiment 1 of the present invention;

[0068] Figures 16A to 16C This is a simulation diagram of the generator motor using fuel oil cooling in Embodiment 1 of the present invention;

[0069] Figure 17A This is a schematic diagram of a motor controller assembly in Example 2;

[0070] Figure 17B for Figure 17A Top view;

[0071] Figure 17C for Figure 17A Partial structural diagram;

[0072] Figure 18A This is a schematic diagram of a cold plate assembly in Example 2;

[0073] Figure 18B for Figure 18A A sectional view;

[0074] Figure 18C for Figure 18B Diagram showing the positional relationship between the upper and lower cooling chambers;

[0075] Figure 19A This is a diagram showing the positional relationship between the power module assembly and the cold plate assembly in Example 2;

[0076] Figure 19B for Figure 19A Another perspective illustration;

[0077] Figure 19C for Figure 19A A sectional view;

[0078] Figure 20A This is a schematic diagram of the capacitor assembly arranged on its side in Example 2;

[0079] Figure 20B This is a schematic diagram of the capacitor assembly near the power module assembly in Example 2;

[0080] Figure 21A This is a schematic diagram of one structure of the electric drive assembly in Example 2;

[0081] Figure 21B for Figure 21A Side view;

[0082] Figure 21C for Figure 21A A schematic diagram of a structure with a shell attached;

[0083] Figure 21D for Figure 21C Exploded view. Detailed Implementation

[0084] The preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings, so as to better understand the purpose, features and advantages of the present invention. It should be understood that the embodiments shown in the drawings are not intended to limit the scope of the present invention, but are only for illustrating the essential spirit of the technical solution of the present invention.

[0085] In the following description, certain specific details are set forth for the purpose of illustrating various disclosed embodiments in order to provide a thorough understanding of the various disclosed embodiments. However, those skilled in the art will recognize that the embodiments may be practiced without one or more of these specific details. In other instances, well-known apparatuses, structures, and techniques associated with this application may not have been shown or described in detail to avoid unnecessarily obscuring the description of the embodiments.

[0086] Throughout this specification, references to "an embodiment" or "an embodiment" indicate that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Therefore, the appearance of "in an embodiment" or "an embodiment" in various places throughout the specification does not necessarily refer to the same embodiment. Furthermore, a particular feature, structure, or characteristic may be combined in any manner in one or more embodiments.

[0087] In the following description, in order to clearly demonstrate the structure and operation of the present invention, a number of directional terms will be used. However, terms such as "front", "back", "left", "right", "outside", "inside", "outward", "inward", "up", and "down" should be understood as convenient terms and not as limiting terms.

[0088] In the following description, the rotation axis of the generator is defined as the forward and backward direction (i.e., Figure 1 In the X-axis direction, where the end where the motor is connected to the engine is the front and the end of the three-phase winding terminals is the rear, the direction perpendicular to the horizontal axis is defined as the left-right direction (i.e., Figure 1 In the Y-axis direction, where, Figure 1 The arrow pointing to the left on the Y-axis and to the right away from the arrow (directions perpendicular to the front-back and left-right directions, respectively) are defined as the up-down direction (i.e., ... Figure 1 (Z-axis direction in the middle).

[0089] Example 1:

[0090] Reference Figures 1 to 13 This invention provides a motor and controller integrated system, which includes a generator motor 10, a controller housing 20, and a motor controller assembly. The motor controller assembly is used to control the operation of the generator motor 10. The motor controller assembly includes a power module assembly 30 and a controller base plate 80. The power module assembly 30 includes several SiC power semiconductor modules 31 and several connecting conductive bars 32, one end of which is electrically connected to the AC terminals of the SiC power semiconductor modules. The other end of the connecting conductive bars 32 is used to electrically connect to the three-phase winding terminals of the generator motor 10. Figure 3 As shown, the three-phase winding terminals of the generator motor 10 are also known as the winding lead-out terminals. The winding lead-out terminals include lead-out terminals U, V, and W. Each phase winding lead-out terminal is connected to a corresponding connecting bus 32. The connecting bus 32 is used to transmit three-phase AC current between the power module 31 and the generator motor 10. The power module 31 is integrated on the controller base plate 80.

[0091] The power module assembly 30 is the core power conversion unit in the motor controller assembly, used to convert electrical energy between the DC bus and the three-phase windings of the generator motor under the drive of the control board assembly. Specifically, the DC terminal of the power module is electrically connected to the DC bus capacitor assembly and the external DC power supply. Under the action of the gate drive signal output by the control board, several SiC power switching devices inside the power module are turned on and off at a preset switching frequency and duty cycle, thereby inverting the DC bus electrical energy into three-phase AC current to supply the three-phase windings of the generator motor, or rectifying the three-phase AC electrical energy output by the generator motor into DC electrical energy and feeding it back to the DC bus under the generator motor operation.

[0092] The motor controller assembly is housed within the controller housing 20, and refers to... Figure 6 The motor controller assembly has a mounting area 20a between its rear and the controller housing 20 for accommodating the connecting conductive busbar 32. The generator motor 10 is fixedly mounted above the controller assembly via the controller housing 20, and the three-phase winding terminals of the generator motor 10 are located at the rear end and / or upper rear region of the generator motor 10. In other words, the generator motor 10 and the motor controller assembly are integrated together via the controller housing 20.

[0093] Several AC terminals of the power module 31 are arranged side-by-side in the installation area. Each AC terminal is electrically connected to a connecting conductive bar 32. Each connecting conductive bar 32 extends axially and / or radially in the installation area and can be bent to achieve spatial avoidance and docking, thereby electrically connecting to the respective three-phase winding terminals of the generator 10 located in the rear end and / or rear upper region. Specifically, each connecting conductive bar 32 can extend upward, backward, and / or outward from the lower AC terminal and bend to dock with the corresponding three-phase winding terminal position.

[0094] like Figures 4 to 8 As shown, the power module assembly 30 includes two power modules 31 and six connecting conductive bars 32. Each connecting conductive bar 32 extends from its upper and lower ends to the AC terminal and the three-phase winding terminal, respectively. A connecting conductive bar 32 electrically connects a single AC terminal to a single three-phase winding terminal. In other words, on each phase, a directly electrically connected relationship is established between the AC terminal of the power module 31 and the corresponding three-phase winding terminal by an integrally formed connecting conductive bar 32, without the need for intermediate connectors, flexible cables, or intermediate terminals.

[0095] With the above structure, the power circuit between the generator motor 10 and the motor controller assembly is entirely composed of the integrally formed connecting conductive bus 32. Compared with the traditional "airplane plug + cable" connection, it reduces the number of contact points and wiring length, reduces the circuit inductance and contact resistance, and at the same time reserves sufficient space for the subsequent addition of an integrated housing on the outside.

[0096] In practical implementation, both the AC terminals and the three-phase winding terminals can be provided with screw holes or welded end faces to reserve positions for rigid connection with the connecting busbar 32. Therefore, when the connecting busbar 32 is electrically connected to the AC terminals and the three-phase winding terminals, it is preferable to achieve the electrical connection by bolt crimping or welding.

[0097] In one embodiment, the three-phase winding terminals of the generator motor 10 can be located at the rear end and / or upper rear region of the motor, and the connecting busbar 32 can extend and be bent and connected in the axial and / or radial direction within the installation area to avoid the limitation of the rigid direct connection scheme by the change of terminal position.

[0098] The three-phase winding terminals of the generator motor 10 are located at the rear end and / or the upper rear area of ​​the generator motor 10. The three-phase winding terminals of the generator motor 10 are rigidly electrically connected to the AC side of the power module assembly 30 of the motor controller assembly through several connecting conductive bars 32, which shortens the three-phase power circuit and reduces stray inductance.

[0099] In this embodiment, "the three-phase winding terminals of the generator motor 10 are located at the rear / rear of the motor" means that the three-phase winding terminals are generally located in the rear region along the axial direction (rotation shaft direction) of the generator motor 10. This region can be located at the rear end face of the generator motor 10, or in the rear upper region near the rear end face of the generator motor 10 (e.g., the terminal area located above the rear of the motor housing), or the terminal / lead-out structure can be provided at both the rear end and the rear upper region. In this embodiment, the connection position of the conductive bus 32 connecting the motor controller assembly and the three-phase winding terminals of the generator motor 10 can be located at the rear end and / or rear upper region of the generator motor 10, depending on the structural layout.

[0100] In one embodiment, a support structure may be provided on the connecting conductive bus 32, and the connecting conductive bus 32 is fixed to a fixing member through the support structure. The fixing member is a relatively stationary device, such as the controller housing 20 or the motor flange of the generator 10. Therefore, it is preferable that the connecting conductive bus 32 is fixed to the controller housing 20 or the motor flange of the generator 10 through the support structure. By providing a support structure on the connecting conductive bus for positioning support, the mechanical strength under vibration environment is improved and the electrical clearance between phases and to ground is ensured.

[0101] In one embodiment, the support structure is an insulating bracket.

[0102] In one embodiment, reference is made to Figure 3 , Figure 7 and Figure 13The controller housing 20 includes a front cover plate 22, a rear cover plate 23, a first side plate 24 and a second side plate 25 arranged along the axial direction, and a top cover 26. The front cover plate 22, the rear cover plate 23, the first side plate 24, the second side plate 25 and the top cover 26 form the controller housing 20.

[0103] The front and rear portions of the generator motor 10 are fixedly connected to the front cover plate 22 and the top cover 26, respectively. Specifically, the front cover plate 22 has a downwardly recessed opening, which is detachably fixed to the lower edge of the flange provided on the front end face of the generator motor 10. The top cover 26 is at a predetermined distance from the front cover plate 22, so that the front part of the top of the controller housing 20 is an open structure with an opening. This open structure accommodates the generator motor 10 and allows the portion of the generator motor from the front to the front edge of the top cover 26 to be exposed outside the controller housing 20. The top cover 26 is an arc-shaped cover with an upward convex center. The top cover 26 covers the rear of the generator motor 10 and the mounting area. The front end of the top cover 26 is detachably fixed to the motor housing of the generator motor 10, and the rear end of the top cover 26 is detachably fixed to the rear cover plate 23. The top cover 26 is designed primarily to seal the three-phase winding terminals of the generator motor 10 to the motor controller assembly, while leaving other parts of the generator motor 10 exposed and unwrapped, thus reducing the overall weight.

[0104] When the generator motor 10 is installed on the controller housing 20, the axis of the generator motor 10 is in the front-to-back direction, and the reserved space 27 is located on the left and right sides of the generator motor 10.

[0105] That is, the controller housing 20 has an installation space in the front-to-back direction in the middle, which is used to install the generator motor 10. The left and right sides of the installation space have reserved spaces 27 for integrating other devices, which are located above the motor controller assembly.

[0106] In one embodiment, reserved spaces 27 for integrating other devices are respectively arranged on the left and right sides of the controller housing 20 along the axial direction of the generator motor. The reserved spaces 27 are located above the motor controller assembly and on the left and right sides of the generator motor 10.

[0107] When the controller housing 20 has a first side plate 24 and a second side plate 25, the reserved space 27 is located on the outside of the first side plate 24 and the second side plate 25.

[0108] In one embodiment, at least one of a fuel pump controller, an oil pump controller, a starter-generator controller, and an engine controller is integrated on the reserved space 27.

[0109] like Figures 1 to 3As shown, in a specific example, a first controller module 91, which integrates the engine controller and the lubricating oil pump controller, is installed in a reserved space on one side of the controller housing 20 along the axis of the generator motor 10. A second controller module 92, which integrates the generator controller and the fuel pump controller, is integrated in a reserved space on the other side of the controller housing 20 along the axis of the generator motor 10.

[0110] In this example, the term "controller module" refers to a controller structure that integrates two or more control function units within the same sealed housing. These control function units can share the housing only in terms of mechanical structure, or they can share some hardware resources at the circuit level. Specifically, they can include the following two typical forms:

[0111] In the first configuration, multiple independent controllers share a single housing:

[0112] In this case, the controller module can adopt a structure where multiple independent controllers share the same housing. For example, one housing space can accommodate two independent control sub-modules: the first control sub-module serves as the starter-generator controller, and the second control sub-module serves as the fuel pump controller. The first and second control sub-modules are independent in both hardware and software, each consisting of its own printed circuit board, power management circuit, microcontroller, and communication interface. They are electrically connected to the starter-generator, fuel pump, and overall control network via their respective external connectors. They share the same aluminum alloy housing and mounting reference surface only in terms of mechanical structure, and can also share the housing's heat dissipation and electromagnetic shielding structures. This shared housing arrangement, compared to using two separate housings, reduces the number of housings and fasteners, saves installation space, and lowers processing and assembly costs, while maintaining the complete electrical independence of the starter-generator controller and the fuel pump controller.

[0113] The second type is a multi-functional controller integrating multiple control units:

[0114] At this point, the controller module can adopt a multi-functional controller structure with multiple control units arranged inside the housing. For example, a starter-generator control unit and a fuel pump control unit can be integrated in the same housing: they are independent in terms of the controlled objects and control algorithms, and are used to drive the starter-generator and fuel pump respectively for status monitoring, but share the same housing, printed circuit board, power filter, and communication interface hardware resources in terms of physical structure. By integrating the functions that could originally be achieved by two independent controllers into a single multi-functional controller module, the number of controllers and housings can be further reduced, the length of signal and power lines can be shortened, the overall wiring complexity and weight can be reduced, and centralized control of actuators such as the engine, starter-generator, and fuel / oil pump can be completed within the limited installation space of the intermediate fuel tank.

[0115] The layout design described in this embodiment not only improves the system's compactness but also effectively shortens the connection lines between components, saving cable costs and reducing signal transmission loss and energy loss.

[0116] The fuel pump controller and oil pump controller are responsible for monitoring the supply status of fuel and oil, ensuring that the engine receives stable and adequate lubrication and cooling under different operating conditions. This is crucial for extending engine life and improving operating efficiency. The fuel pump controller, oil pump controller, and related accessories can be directly integrated into the controller housing 20 of this invention using existing technology, and will not be described in detail here.

[0117] The starter generator controller serves a dual purpose: starting the engine and, when necessary, acting as a generator to supply power to the system. By precisely controlling the speed and torque of the starter motor, the starter generator controller ensures a smooth engine start. Simultaneously, during flight or when stationary on the ground, it switches to generator mode as needed, providing stable power support to onboard equipment. The starter generator controller can be directly integrated into the controller housing 20 of this invention using existing technology, and will not be elaborated further here.

[0118] The engine controller receives data from various sensors, including but not limited to key parameters such as temperature, pressure, and engine speed. After analysis using a preset algorithm, it precisely adjusts fuel injection quantity, intake air volume, and ignition timing to ensure the engine always operates at its optimal state, achieving efficient and low-emission power output. The engine controller can be directly integrated into the controller housing 20 of this invention using existing technology, and will not be elaborated further here.

[0119] In one embodiment, reference is made to Figure 4 , Figure 6 and Figure 7 The bottom of the controller base plate 80 is equipped with heat dissipation teeth 28 to achieve air cooling.

[0120] In one embodiment, a cooling fan is provided on the side of the heat dissipation fins 28 to further improve the heat dissipation effect. The controller base plate 80 adopts a U-shaped structure, and the cooling fan can be installed on the side wall of the controller base plate 80.

[0121] In one embodiment, reference is made to Figure 2 The generator motor 10 has a flange 11 on its front end face and an internal spline 12 for transmission in the middle of its front end. The flange 11 and the internal spline 12 are used to connect the generator motor 10 and the engine.

[0122] In this embodiment, the integrated system is positioned and installed using the flange stop and bolts of the generator 10, and transmission is achieved through internal spline connection. Depending on the actual engine interface, the flange size, bolt connection method, and spline adapter are adjusted to connect engines of different types and power. This allows for flexible assembly by setting different flange sizes and spline interfaces for the generator 10 ports, enabling connection to different engines.

[0123] This embodiment greatly expands the application range of the system due to its compatibility with different types and power engines. Whether it is a small single-shaft engine or a dual-shaft engine, stable and reliable connection and transmission can be achieved by adjusting the corresponding flange size, bolt connection method and spline adapter according to its interface characteristics. This not only reduces the cost and time of developing matching systems for different engines, but also improves the system's versatility and maintainability.

[0124] In one embodiment, reference is made to Figure 11 and Figure 12 The generator 10 has an internal lubricating oil cooling channel. The controller base plate 80 has an oil inlet 29 and an oil outlet on its side wall. Preferably, the controller base plate 80 adopts a U-shaped structure. The oil inlet 29 and oil outlet are connected to the inlet and outlet of the lubricating oil cooling channel of the generator 10, respectively. The oil pump 93 is connected to the outlet of the oil tank via a pipeline, to the inlet of the heat exchanger via a pipeline, to the outlet of the heat exchanger via a pipeline, and to the oil inlet 29 via a pipeline. The oil outlet is connected to the return port of the oil tank via a pipeline, thus realizing a lubricating oil circuit. The lubricating oil pump 93 sends lubricating oil from the lubricating oil tank into the heat exchanger. After heat exchange in the heat exchanger, the lubricating oil is further cooled. The lubricating oil pump 93 then sends the lubricating oil through the pipeline and the lubricating oil inlet 29 into the lubricating oil cooling channel. After cooling and lubricating the relevant hot spots inside the generator motor 10, such as bearings, the lubricating oil is sent back to the lubricating oil tank through the lubricating oil outlet.

[0125] In this embodiment, the lubricating oil is supplied by an external lubricating oil tank. After being cooled by a heat exchanger, the lubricating oil enters the generator motor 10, thereby achieving direct cooling of various related hot spots (such as bearing installation points) inside the generator motor 10 through the lubricating oil and the lubricating oil pump 93, ensuring that each component can work efficiently and for a long time when running at high speed.

[0126] Specifically, the lubricating oil cooling channels of the generator motor 10 can be connected to all relevant hot spots. During the continuous operation of the generator motor 10, the lubricating oil circulates between these hot spots, precisely carrying away the heat generated by high-speed friction and current. This lubricating oil cooling method not only effectively reduces the temperature of the parts but also forms a stable and tough lubricating film on the surface of the parts, greatly reducing wear between them. The presence of this lubricating film allows the generator motor 10 to maintain stable performance output under long-term high-load operation, with minimal fluctuations in various parameters.

[0127] In one embodiment, reference is made to Figure 5 The power module assembly 30 also includes a phase current sensor 33 for detecting phase current. In this embodiment, by placing the phase current sensor 33 on the power path, the distance between the control board and the power module is short, the control loop delay is small, which is beneficial for high-frequency precise control.

[0128] In practical implementation, the phase current sensor 33 can be placed on the connection path between the AC terminal of the power module and the connecting busbar. For example, an AC busbar can be added between the AC terminal of the power module and the connecting busbar, with one end of the AC busbar electrically connected to the AC terminal and the other end of the AC busbar electrically connected to the connecting busbar. The phase current sensor 33 is placed on the AC busbar to detect the phase current of the AC busbar. The signal output terminal of the phase current sensor 33 is connected to the control board of the control board assembly.

[0129] Of course, each AC terminal of the power module is equipped with a corresponding phase current sensor 33 to detect the phase current of each phase.

[0130] In one embodiment, reference is made to Figures 6 to 8 The controller base plate 80 has a length direction that is horizontally perpendicular to the axis of the generator motor 10, and a width direction that is parallel to the axis of the generator motor 10, preferably adopting a U-shaped structure. The controller base plate 80 is fixed below the generator motor 10, so that the entire motor controller assembly is located in the lower central area of ​​the generator motor 10, thereby forming reserved spaces 27 on the left and right sides of the generator motor 10 for arranging other controllers or accessories.

[0131] The power module assembly 30 is located in the central area of ​​the controller base plate 80. The length direction of each power module 31 in the power module assembly 30 is left-right, and several power modules 31 are mounted side-by-side on the controller base plate 80 along the left-right direction. For example... Figure 5 and Figure 7 As can be seen, the power modules 31 of the power module assembly 30 are arranged side by side at the same height.

[0132] The DC bus capacitor assembly 40 includes several DC capacitors and interconnecting busbars electrically connected to each DC capacitor, and is equipped with a bus current sensor for detecting the DC bus current. Several DC capacitors are arranged side-by-side in the left-right direction on the front side of the controller base plate 80, i.e., in front of the power module assembly 30. An interconnecting busbar is arranged behind them. Several connection points are provided on the side of the interconnecting busbar facing the power module assembly 30, for connecting the positive and negative terminals of the several DC capacitors in parallel to form a DC bus capacitor group. The connection points on this side provide electrical connection interfaces with the DC busbar and external DC power supply interface. The DC terminals of the power modules 31 are located on the front side of each power module 31. The positive and negative DC terminals of the power modules 31 are electrically connected to the corresponding connection points of the interconnecting busbars through positive and negative DC busbars, respectively.

[0133] The arrangement and connection method of the DC bus capacitor assembly 40 and the power module assembly 30 described above have the following beneficial effects:

[0134] First, since several DC capacitors are arranged side by side in the left-right direction, their interconnecting busbars and the connection points of the DC busbars connected to them are concentrated on one side near the rear end of the generator motor 10. This makes the DC bus capacitor assembly 40 and the power module assembly 30 form a power unit strip on the controller base plate 80 that extends in the left-right direction and converges towards one end of the generator motor 10. On the one hand, this can reduce the space occupied by the controller in the front-back direction, so that the motor controller assembly can be compactly arranged in the middle area below the generator motor 10, which facilitates the integrated installation of the generator motor and the controller. On the other hand, the three-phase AC terminals of the power module 31 and the three-phase winding terminals of the generator motor 10 are also concentrated on one side near the rear end of the generator motor. The three-phase output busbar can extend directly upward from this side and be rigidly connected to the generator motor terminals without the need for wiring across the DC capacitor area. This further shortens the spatial distance between the generator motor and the motor controller assembly, reduces the number and length of high-current connectors, and improves the space utilization and integration of the whole machine.

[0135] Secondly, several DC capacitors are arranged side by side in the left-right direction, and an interconnecting bus is set on the rear side of them. The DC terminals of the power module 31 are directly connected to the interconnecting bus via a short-pitch DC bus. This forms a DC bus loop with a very short path and a small loop area between the DC capacitor bank and the DC terminals of the power module. This is beneficial to significantly reduce the equivalent inductance of the DC bus loop, reduce the spikes and oscillations of the bus voltage during switching, and improve the electromagnetic compatibility performance and reliability of the power module under high-frequency switching conditions.

[0136] The bus current sensor is preferably installed on one of the DC busbars or interconnecting busbars. It can directly collect the bus current in the main circuit of the DC busbar, realize accurate monitoring of the input current of the power module, and provide reliable detection signals for DC busbar overcurrent protection, power limiting and fault diagnosis, further improving the safety and intelligence level of the motor controller components.

[0137] The external DC power interface 211 is connected to another connection point of the interconnecting bus via a short-circuit copper bus or wire, so that the external DC power supply, the DC bus capacitor bank, and the DC terminals of the power module assembly 30 together form a DC bus circuit. In this way, since the interconnecting bus is electrically connected to several DC capacitor terminals, the DC bus, and the external DC power interface 211 through multiple connection points, the above components are electrically located at the same bus node. On the one hand, this facilitates current and voltage sharing among multiple DC capacitors, avoids excessive ripple current on a single capacitor, and extends the service life of the DC bus capacitor bank. On the other hand, it simplifies the wiring path between the external DC power supply and the power module, reduces the number of high-current wires and connectors, and helps to improve the compactness and assembly reliability of the overall structure.

[0138] In practical implementation, the positive and negative DC busbars are preferably plate-shaped copper strips, separated by an insulating component to ensure sufficient electrical clearance and reduce the equivalent inductance of the DC bus circuit. The DC capacitors in the DC bus capacitor assembly 40 are arranged close to the DC terminals of each power module 31, forming a shorter DC bus circuit. This circuit smooths the DC bus voltage, provides transient energy for power module switching, and suppresses DC bus voltage ripples and spikes. The power module assembly 30, driven by the control board, performs energy conversion between DC and three-phase AC. An AC busbar located on the controller base plate 80 near the generator 10 transmits large three-phase current between the AC terminals of the power module assembly and the three-phase winding terminals of the generator 10, achieving a rigid conductive connection.

[0139] In this application, to facilitate the description of the installation posture of the capacitor assembly, the main plane of the capacitor assembly 40 is defined as: the largest outer surface of the capacitor assembly shell (i.e., the large rectangular surface formed by the width × length of the capacitor assembly, which can also be understood as the side of the capacitor assembly that is basically parallel to the plane of the controller base plate when it is laid flat).

[0140] In this embodiment, the capacitor assembly 4 is usually arranged flat, that is, the main plane of the capacitor assembly 40 is basically parallel to the bottom plane of the controller base plate 80, so that the capacitor assembly occupies a large projected area in the base plate plane.

[0141] A DC power interface 211 is provided on the side wall (one side of the U-shaped structure) of the controller base plate 80. The DC power interface 211 is electrically connected to the power input terminal of the DC bus capacitor assembly 40 and is used to introduce external DC power into the DC bus capacitor assembly 40.

[0142] In a preferred embodiment, the connecting busbar 32, the DC busbar, and the interconnecting busbar are all made of copper to reduce conductivity loss and improve mechanical rigidity. Of course, in another embodiment, the aforementioned busbars can also be made of aluminum or other conductive materials with good conductivity; this invention does not limit this.

[0143] like Figure 7 As shown, the motor controller assembly also includes a control board assembly 50, which includes a control board for driving the power modules 31 and an outer shielding plate disposed on the outside of the control board. The control board is electrically connected to several power modules 31 and phase current sensors via wiring harnesses or board-to-board connectors. The control board assembly 50 can be disposed above or to the side of several power modules 31, or above or to the side of several DC capacitors; preferably, the control board assembly 50 is disposed above several power modules 31 to shorten the wiring length between the control board and the power modules, reduce control loop delay, and facilitate high-frequency precise control.

[0144] The controller base plate 80 also has a controller power supply interface 210 on its side wall surface. The controller power supply interface 210 is used to provide low-voltage power to the control board assembly 50 and can also serve as a debugging and calibration interface. The pins of the controller power supply interface 210 are electrically connected to the control board via a wiring harness. In specific implementations, the low-voltage power supply interface and the debugging interface can be integrated into a single controller power supply interface 210, thereby saving a separate aviation plug interface.

[0145] like Figure 7 As shown, the motor controller assembly may also include a shielding partition 60. When the control board assembly 50 is arranged above several power modules 31, the shielding partition 60 is arranged above the control board assembly 50 to shield the electromagnetic coupling between the control board assembly 50 and the external environment, thereby improving the electromagnetic compatibility performance of the controller assembly under high voltage and high current conditions.

[0146] In one embodiment, reference is made to Figure 7The controller base plate 80 extends horizontally along its length and vertically along its width. The power module assembly 30 also includes a cold plate 70, which has internal liquid cooling channels. The cold plate 70 extends horizontally along its length and is mounted on the controller base plate 80. The power module 31 is mounted on the cold plate 70, and its length also extends horizontally. When the liquid cooling medium flows through the internal liquid cooling channels of the cold plate 70, heat exchange occurs between the liquid cooling medium and the power module 31, thus cooling the power module 31.

[0147] In this embodiment, the power module components are uniformly mounted on a cold plate 70 with internal liquid cooling channels. The cold plate 70 is fixed to the controller base plate 80, and the cold plate 70 and the controller base plate 80 together bear mechanical loads and vibrations. Liquid cooling medium is circulated inside the cold plate 70 to cool the power module components. The cold plate 70, the controller base plate 80, and the vertical connecting conductive busbar 32 form a mutually supporting integrated frame.

[0148] like Figure 7 As shown in this embodiment, six power module components are arranged side by side on a cold plate 70.

[0149] In one embodiment, the power module assembly 30 includes a plurality of power module units, as shown in the figure. Figure 14 A single power module unit includes a power module 31, a current sensor 34, and an AC bus 35. The current sensor 34 is used to detect the phase current and / or branch current of the power module 31 to meet control and protection requirements. When the current sensor 34 is used to detect the phase current of the power module 31, it is also called a phase current sensor 33. The AC bus 35 is electrically connected to the AC terminals of the power module 31, so that the AC terminals of the power module 31 can be electrically connected to the corresponding connecting bus 32 via the AC bus 35.

[0150] In one embodiment, reference is made to Figure 14 Each power module unit also includes a power busbar 36, which is electrically connected to the DC terminals of the power module 31 so that the DC terminals of the power module 31 can be electrically connected to the DC bus capacitor assembly 40 via the power busbar 36.

[0151] In one embodiment, the connection busbar 32 of the motor controller assembly is electrically connected to the AC side of the power module assembly 30 ("AC side of the power module" refers to the terminal side (U / V / W phase terminal) of the power module used for outputting / inputting three-phase AC power, corresponding to the DC terminal side (DC+ / DC-) of the power module) via AC busbar 35.

[0152] In one embodiment, the liquid cooling medium is fuel oil, used to cool the power module components.

[0153] In this embodiment, the liquid cooling medium introduced into the cold plate is the fuel already present in the engine system, which can achieve liquid cooling by fuel cooling method without the need to set up a new cooling circuit, reducing system complexity and added mass.

[0154] In one embodiment, a fuel cooling channel is provided inside the motor housing of the generator motor 10. The inlet of the liquid cooling channel of the cold plate 70 is connected to the fuel pump 94 via a pipeline, and the outlet of the liquid cooling channel of the cold plate 70 is connected to the inlet of the fuel cooling channel of the generator motor 10 via a pipeline. The outlet of the fuel cooling channel of the generator motor 10 is also connected to the fuel pump 94 via a pipeline. The fuel pump delivers fuel through the pipeline into the liquid cooling channel to cool the power module 31. After cooling the generator motor 10, the fuel is then delivered through the pipeline into the fuel cooling channel. Finally, the fuel is pumped from the fuel cooling channel by the fuel pump 94 to the engine for combustion.

[0155] In this embodiment, when the liquid cooling medium is fuel oil, the fuel oil first cools the motor controller assembly, especially the power module, and then is used to cool the motor housing of the generator motor 10 before finally being delivered to the engine for combustion.

[0156] In specific implementation, refer to Figure 9 and Figure 10 The controller housing 20 is provided with a fuel inlet 212 and a fuel outlet 213. The fuel inlet 212 and the fuel outlet 213 are respectively connected to the liquid cooling channel inlet and liquid cooling channel outlet of the cold plate. The fuel inlet 212 is connected to the fuel pump 94 through a pipeline. The fuel outlet 213 is connected to the fuel cooling channel inlet of the generator motor 10 through a pipeline. The fuel cooling channel outlet of the generator motor 10 is connected to the fuel pump 94 through a pipeline. The fuel pump 94 sends fuel from the external fuel tank into the liquid cooling channel of the cold plate 70 through the pipeline and the fuel inlet 212 to cool the power module. After cooling, the fuel is sent into the fuel cooling channel of the generator motor 10 through the pipeline. The generator motor 10 is cooled by the motor windings and magnets in the generator motor 10. Then, the fuel is sent out from the fuel cooling channel to the engine for combustion through the fuel pump 94.

[0157] In this embodiment, when the controller housing 20 has a reserved space 27, the fuel pump controller of the fuel pump 94 is preferably disposed in the reserved space 27 on the controller housing 20.

[0158] Reference Figure 15 This is a simulation diagram showing the fuel flow to the cold plate 70 where the power module assembly 30 is located. The simulation temperature parameters are shown in the table below:

[0159]

[0160] Reference Figures 16A to 16C This is a simulation diagram showing the fuel flow to the generator 10. Figure 16A This is a schematic diagram simulating the surface temperature of the motor housing. Figure 16B This is a simulation diagram of the surface temperature of the motor windings. Figure 16C This is a simulation diagram of the surface temperature of the magnet. The simulation temperature parameters are shown in the table below:

[0161]

[0162] In the table above, the fuel inlet refers to the fuel cooling channel inlet of the motor housing, and the fuel outlet refers to the fuel cooling channel outlet of the motor housing.

[0163] It is evident that when the fuel temperature at the inlet of the fuel cooling channel is 80°C, it can meet the heat dissipation requirements of the generator motor 10 and the power module assembly 30, and can be used as the cooling liquid for the motor controller assembly of the present invention.

[0164] Example 2:

[0165] This invention provides a motor controller assembly. Compared with the motor controller assembly of Embodiment 1, this embodiment 2 makes the following main improvements without changing the overall framework of Embodiment 1, such as "vertical stacking and integration of the generator and the motor controller assembly, rigid direct connection through the connecting busbar, and liquid cooling heat dissipation with the cold plate serving as a load-bearing platform":

[0166] (1) The power module arrangement was changed from a single-layer arrangement to a double-layer / double-sided arrangement.

[0167] (2) The DC bus capacitor assembly was changed from a flat arrangement to a side-standing arrangement, further reducing its projection footprint on the controller base plate.

[0168] Reference Figures 17A to 20B The motor controller assembly in this embodiment includes a power module assembly 30a, a capacitor assembly 40a, a cold plate assembly 70a, and a controller base plate 80a.

[0169] The cold plate assembly 70a is mounted on the controller base plate 80a. In a specific implementation, there is a certain distance between the bottom surface of the cold plate assembly 70a and the side surface of the controller base plate 80a, and between the side surface of the controller base plate 80a and the bottom plane of the controller base plate 80a. This distance is used for mounting the lower power module assembly. The cold plate assembly 70a can be fixed to the side wall of the controller base plate 80a at one or both ends along its length using fasteners such as bolts.

[0170] The power module assembly 30a includes a plurality of power modules 31a, which are SiC power semiconductor power modules. The plurality of power modules 31a are distributed and mounted on the upper and lower surfaces of the cold plate assembly 70a along the thickness direction, thereby forming an upper power module group and a lower power module group on the upper and lower surfaces of the cold plate assembly 70a, respectively. The upper power module group and the lower power module group form a thermally conductive fit with the cold plate assembly 70a.

[0171] As can be seen, the main difference between the power module 31a in this embodiment and the power module 31 in embodiment 1 is that the distribution on the cold plate assembly 70a is different: the single-layer arrangement in embodiment 1 is changed to a double-layer or double-sided arrangement. In this way, compared with the single-layer arrangement in embodiment 1, for the same number of power modules, the projected area on the bottom plate plane of the controller base plate 80a can be reduced, thereby greatly reducing the overall length of the motor controller assembly in the left and right direction (that is, the horizontal direction perpendicular to the rotating shaft), achieving the goal of highly integrated and miniaturized motor controller assembly.

[0172] Specifically, such as Figures 19A to 19C As shown, the upper power module group includes power modules 31A, 31B, and 31C, and the lower power module group includes power modules 31D, 31E, and 31F. The upper and lower power module groups are arranged in layers along the thickness direction of the cold plate assembly 70a, located on the upper and lower surfaces of the cold plate assembly 70a, respectively. The surfaces of the cold plate assembly 70a that are in contact with the power modules can be made of thermally conductive interface materials and secured with fasteners to ensure stable thermal contact. Alternatively, cooling grooves can be created, allowing the power modules to be directly embedded in the cooling grooves and exchange heat with the cooling liquid.

[0173] The capacitor assembly 40a is mounted sideways on the controller base plate 80a to reduce the projected footprint of the capacitor assembly 40a on the controller base plate 80a. In embodiment 2, the capacitor assembly 40a differs from the capacitor assembly 40 in embodiment 1 in that it is mounted sideways, i.e., the main plane of the capacitor assembly forms an angle α with respect to the plane of the base plate. The angle α is as close as possible to or equal to 90°, so that the capacitor assembly is arranged in an approximately vertical posture, which significantly reduces the projected footprint of the capacitor assembly on the bottom plane of the controller base plate 80a and frees up space in the plane of the base plate for arranging upper / lower layer power module groups or other controller modules.

[0174] Specifically, the capacitor assembly 40a is located in front of the cold plate assembly 70a and the power module assembly 30a, and the capacitor assembly 40a is electrically connected to each power module 31a through a DC bus assembly.

[0175] like Figure 20AAs shown, the capacitor assembly 40a is arranged in a side-standing manner inside the controller housing. Its relative positional relationship with the controller base plate 80a and the housing space is clear, thereby reducing the footprint in the base plate projection plane and creating conditions for freeing up installation space in the area below or around it.

[0176] like Figure 17B The diagram shown is a plan view of the components on the controller base plate 80a in this embodiment, which is different from that in Embodiment 1. Figure 8 In comparison, this embodiment further reduces the footprint of the controller base plate 80a by using the power module 31a in a double-layer distribution (upper power module group / lower power module group), the cold plate assembly 70a for corresponding heat dissipation, and the capacitor assembly 40a arranged on the side and connected to the upper and lower power conductors respectively. This allows the controller base plate 80a to free up a larger installation area.

[0177] In one example, the released mounting area is a reserved mounting area 81a on the front side of the capacitor assembly 40a. The reserved mounting area 81a can be used to install a starter-generator controller and / or a DC / DC controller and / or other electric drive controller modules 82a, such as the fuel pump controller, lubricating oil pump controller, starter-generator controller, and engine controller of Embodiment 1. In this way, compared with Embodiment 1, the reserved space 27 for installing other controller modules is no longer reserved on both sides of the controller housing, nor is it necessary to reserve reserved space 27 through the side plates. The space to accommodate the motor 10a and the motor controller assembly 100 can be formed simply by the controller upper shell 83a, the controller bottom plate 80a, and the tail cover 84a, which further reduces the footprint and the production cost of the controller housing.

[0178] In one specific embodiment, compared with embodiment 1, this embodiment further makes the following main improvements: the cold plate assembly 70a forms an upper cooling cavity and a lower cooling cavity, which correspond to the heat exchange of the upper power module group and the lower power module group, respectively, so as to adapt to the heat dissipation of the dual-layer power device and improve the temperature balance.

[0179] Reference Figures 18A to 18C The upper and lower surfaces of the cold plate assembly 70a are respectively provided with a plurality of opening slots for connecting the power modules 31a. Inside the cold plate assembly 70a, there are upper cooling chambers 71a and lower cooling chambers 72a that communicate with the opening slots on the same side. The upper cooling chamber 71a is the heat exchange area for the upper power module group, and the lower cooling chamber 72a is the heat exchange area for the lower power module group. In this embodiment, the upper and lower power module groups exchange heat with the upper cooling chambers 71a and lower cooling chambers 72a inside the cold plate assembly 70a respectively through a cooling medium, thereby increasing power density and improving heat dissipation uniformity without significantly increasing the footprint of the controller base plate 80a.

[0180] In this embodiment, the upper cooling cavity 71a and the lower cooling cavity 72a are distributed at different heights in cross-section, thus corresponding to the heat exchange areas of the upper power module group and the lower power module group, respectively. Figure 18B As shown, the upper cooling cavity may include upper cooling cavity 71A, upper cooling cavity 71B and upper cooling cavity 71C, and the lower cooling cavity may include lower cooling cavity 72D, lower cooling cavity 72E and lower cooling cavity 72F, for heat exchange with power module 31A, power module 31B, power module 31C, power module 31D, power module 31E and power module 31F respectively.

[0181] In this specific implementation, the cold plate assembly 70a is provided with an inlet IN and an outlet OUT. The cooling medium enters the interior of the cold plate assembly 70a through the inlet and flows out through the outlet.

[0182] In a specific implementation of this embodiment, in one example, the cooling circuits of the upper cooling cavity 71a and the lower cooling cavity 72a are parallel shunt circuits and / or series circuits. The specific configuration can be selected based on the thermal load and flow resistance matching of the two power modules.

[0183] The parallel flow distribution circuit refers to the fact that the upper cooling chamber 71a and the lower cooling chamber 72a are independent of each other, and are only connected at the inlet and outlet. In other words, after the cooling medium enters the cold plate assembly 70a through the inlet, it flows into the upper cooling chamber 71a and the lower cooling chamber 72a on the upper and lower sides respectively. After heat exchange with each power module 31a, the cooling medium converges at the outlet on the upper and lower sides respectively and flows out. Therefore, the cold plate assembly 70a has two cooling channels inside, one upper and one lower.

[0184] A series circuit refers to a situation where, within the cold plate assembly 70a, the upper cooling cavity 71a and the lower cooling cavity 72a have one or more interconnected series flow channels, or are directly interconnected, meaning they are connected within the cold plate assembly 70a. In other words, after the cooling medium enters the cold plate assembly 70a through the inlet, it flows into the upper cooling cavity 71a and the lower cooling cavity 72a on both sides, mixing with each other. After heat exchange with each power module 31a, the mixed cooling medium flows out through the outlet. Thus, the cold plate assembly 70a has an upper layer and two interconnected cooling flow channels.

[0185] In a specific implementation of this embodiment, in one example, a sealing groove and / or sealing device are provided at the edge of the opening groove, and the power module 31a is sealed to the opening groove. A sealing groove design is preferred to accommodate a sealing ring or equivalent sealing structure within the sealing groove, thereby achieving cavity sealing. For example... Figure 18BAs shown, sealing grooves are provided on the edges of the three upper opening grooves and the three lower opening grooves, namely the upper sealing grooves 73A, 73B, and 73C, and the lower sealing grooves 73D, 73E, and 73F, respectively, for sealing connection with power modules 31A, 31B, 31C, 31D, 31E, and 31F.

[0186] In a specific implementation of this embodiment, in one example, refer to... Figure 18A and Figure 18C The cold plate assembly 70a includes a cold plate body 74a, the surface of which is provided with an opening groove, and the interior of the cold plate body 74a is provided with an upper cooling chamber 71a and a lower cooling chamber 72a. The side wall of the cold plate body 74a is provided with a water inlet and a water outlet.

[0187] Reference Figure 19A and Figure 19B The cold plate assembly 70a also includes several pressure plates 75a for connecting the power module 31a to the opening slot, and the pressure plates 75a are detachably connected to the cold plate body 75a.

[0188] The power module 31a can be detachably and sealed onto the opening slot using the pressure plate 75a. In use, the pressure plate 75a can be used to press down on the side of the power module 31a to secure it.

[0189] The pressure plate 75a and the cold plate body 74a can be detachably connected by fasteners such as bolts or screws.

[0190] In a specific implementation of this embodiment, in one example, a pressure plate 75a is respectively provided on two opposite sides of the same side of the cold plate body 74a. When there are several opening slots, the adjacent sides of two adjacent opening slots share the same pressure plate 75a.

[0191] The pressure plate 75a adopts an inverted L-shaped or T-shaped structure. Depending on the structure of the pressure plate 75a, the independent pressure plate and the shared pressure plate can have the same or different structures. For example, the independent pressure plate structure adopts an L-shaped structure, while the shared pressure plate structure adopts a T-shaped structure.

[0192] In a specific implementation of this embodiment, in one example, refer to... Figure 18A The cold plate assembly 70a also includes a plurality of positioning holes 76a, which are preferably respectively disposed on the cold plate body 74a on the side of the opening groove.

[0193] The cold plate assembly 70a also includes several positioning posts that correspond to the positioning holes 76a. These positioning posts are used for positioning and mounting the power module 31a. The positioning posts serve as guides and positions during the installation of the power module 31a.

[0194] In practice, one end of the positioning post is inserted into the positioning hole 76a. Alternatively, another positioning hole can be drilled in the power module 31a so that the other end of the positioning post is inserted into that other positioning hole.

[0195] In a specific implementation of this embodiment, in one example, the cold plate assembly 70a is made of a thermally conductive material such as aluminum in order to better transfer heat.

[0196] In one embodiment, compared with embodiment 1, the following main improvements are made: the specific shape of the three-phase busbar 32a, and the connection position between the three-phase busbar 32a and the power module assembly 30a.

[0197] Compared with the connecting busbar 32 in Embodiment 1, the three-phase busbars 32a in this embodiment are connected to power modules of different heights by means of length misalignment.

[0198] In this embodiment, the power module assembly forms an upper power module group and a lower power module group along the thickness direction of the water-cooled plate assembly. The motor controller assembly has a three-phase connection terminal area on its rear side, the position of which substantially coincides with the upper and lower power module groups in planar projection. Because the upper and lower power module groups have different heights / distances relative to the terminal area, the three-phase busbars corresponding to the upper and lower power module groups have different extension lengths and / or different bending heights. Furthermore, to avoid spatial interference between the two sets of busbars near the terminal area, at least one set of busbars is provided with a clearance structure, including window notches, stepped bends, and / or offset arrangements, so that the two sets of busbars achieve rigid electrical connections with the corresponding connection positions in the terminal area in a staggered or offset manner, and the phase-to-phase and phase-to-ground electrical clearances are ensured by insulating isolation components; or, as... Figure 21A As shown, by making the AC busbars 35a of the two corresponding power modules bend in different directions at the ends away from the power modules, the ends of the two AC busbars 35a are staggered so that they can be electrically connected to the two three-phase busbars 32a respectively without mutual interference.

[0199] The electrical connection between the three-phase busbar 32a and the power module can be the same as or similar to that in Embodiment 1, where "power module AC terminal - connecting busbar - motor three-phase winding terminal".

[0200] In one embodiment, compared with embodiment 1, the following main improvements are made: To adapt to the side-standing arrangement of the dual-layer power modules and capacitor components, the power module unit located in the upper layer and the power module unit located in the lower layer can be respectively provided with corresponding power busbars 36. The capacitor component 40a is connected to the power busbars 36 corresponding to the power modules 31a in the upper layer and the power busbars 36 corresponding to the power modules 31a in the lower layer through the DC busbar component, thereby providing DC support to the upper power module group and the lower power module group at the same time.

[0201] Specifically, the DC bus assembly is led out from the DC+ and DC- terminals of the capacitor assembly 40a, and is provided with upper and lower connection terminals respectively, so as to connect with the power bus 36 of the upper power module unit and the power bus 36 of the lower power module unit respectively, thereby simultaneously supplying power to the upper and lower power module units and keeping the DC loop compact without additional detours or significantly lengthening the conductive path.

[0202] In a specific implementation of this embodiment, in one example, the DC bus assembly can be a plate-shaped copper bus. The DC bus assembly includes a DC positive bus and a DC negative bus, and an insulating layer is sandwiched between the DC positive bus and the DC negative bus to form a stacked bus structure, so as to reduce the DC circuit area and improve compactness and electromagnetic interference resistance.

[0203] In a specific implementation of this embodiment, in one example, refer to... Figure 20B The DC input terminals of capacitor assembly 40a include DC input DC+ and DC input DC-. Electrical energy enters the DC bus where capacitor assembly 40a and power module group are located via DC input.

[0204] In a specific implementation of this embodiment, in one example, the capacitor assembly 40a is fixed to the controller base plate 80a by a bracket (or fixing screws / fastening structure). The bracket has a vibration-resistant reinforcement structure and / or a terminal insulation protection structure to meet the requirements of electrical clearance and creepage distance.

[0205] This invention also provides an electric drive assembly, see reference. Figures 21A to 21D The electric drive assembly includes a motor 10a and a motor controller assembly 100 for controlling the motor 10a. The motor controller assembly 100 adopts the motor controller provided in various embodiments of Embodiment 2 of the present invention. The motor controller assembly 100 is installed below or to the side of the motor 10a and forms a longitudinally stacked integrated structure with the motor 10a.

[0206] The electric drive assembly in this embodiment also includes a support base 200 and a controller housing, with the front end of the motor 10a extending out from the front of the controller housing. The controller housing includes a controller base plate 80a (also referred to as the controller lower housing, having the aforementioned bottom plate plane 80b), a controller upper housing 83a, and a tail cover 84a. The controller base plate 80a, controller upper housing 83a, tail cover 84a, and support base 200 together form a receiving space for accommodating the motor 10a and the motor controller assembly 100.

[0207] One assembly step of the electric drive assembly of the present invention is as follows:

[0208] Step S1: Pre-install the three-phase busbar 32a onto the controller base plate 80a. The pre-installation position of the three-phase busbar 32a is located inside the final formed controller housing. Then, install the cold plate assembly 70a, the upper power module group and the lower power module group in the power module assembly 30a, the capacitor assembly 40a, etc., in the corresponding layout positions of the controller base plate 80a.

[0209] Step S2: Secure the support base 200 to the side and / or back of the motor flange 11a of the motor 10a with screws.

[0210] Step S3: The motor controller assembly 100 formed in step S1 is installed on the support base 200 through the controller base plate 80a, and the motor controller assembly 100 is rigidly electrically connected to the three-phase winding terminals of the motor 10a at the tail or rear upper region through the three-phase busbar 32a.

[0211] Step S4: Seal the front side of the controller upper housing 83a to the motor flange 11a, and seal the bottom end of the controller upper housing 83a to the top end of the controller base plate 80a to achieve sealing and protection.

[0212] Step S5: Seal and fix the rear side of the controller upper shell 83a and the rear side of the controller base plate 80a onto the tail cover 84a respectively to complete the final assembly.

[0213] This invention also provides a hybrid powertrain, which includes an engine and an electric drive assembly. The electric drive assembly adopts the electric drive assembly provided in various embodiments of this invention. The engine converts thermal energy into mechanical energy through combustion, driving the shaft of the motor 10a to rotate to output electricity.

[0214] In one example, the engine may sequentially include necessary components such as an intake shroud, diffuser, guide vanes, combustion chamber, gas turbine, power turbine, and exhaust casing assembly. The gas turbine is connected to the compressor via a rotating shaft. The gas entering the combustion chamber from the compressor burns and expands, driving the gas turbine to rotate. The power turbine is coaxially connected to the electric motor via a spline. The high-temperature, high-pressure gas generated by the rotation of the gas turbine drives the power turbine to rotate, thereby rotating the coaxial part and driving the electric motor shaft to rotate for electrical energy output.

[0215] The preferred embodiments of the present invention have been described in detail above. However, it should be understood that after reading the above teachings, those skilled in the art can make various alterations or modifications to the present invention. These equivalent forms also fall within the scope defined by the appended claims.

Claims

1. A motor controller assembly, characterized in that, The motor controller assembly includes: Controller base plate; A cold plate assembly is disposed on the controller base plate; A power module assembly, comprising a plurality of power modules, wherein the plurality of power modules are distributed and mounted on the upper and lower surfaces of the cold plate assembly along the thickness direction of the cold plate assembly, thereby forming an upper power module group and a lower power module group on the upper and lower surfaces of the cold plate assembly, respectively, wherein the upper power module group and the lower power module group form a thermally conductive fit with the cold plate assembly. A capacitor assembly is mounted sideways on the controller base plate to reduce the footprint of the capacitor assembly on the controller base plate. The capacitor assembly is located in front of the cold plate assembly and the power module assembly. The capacitor assembly is electrically connected to each of the power modules through a DC bus assembly.

2. The motor controller assembly as described in claim 1, characterized in that, The upper and lower surfaces of the cold plate assembly are respectively provided with a plurality of opening slots for connecting the power modules. The interior of the cold plate assembly is respectively provided with an upper cooling cavity and a lower cooling cavity that communicate with the opening slots on the same side. The upper cooling cavity is the heat exchange area of ​​the upper power module group, and the lower cooling cavity is the heat exchange area of ​​the lower power module group. Preferably, the cooling circuits of the upper cooling chamber and the lower cooling chamber are parallel flow-dividing circuits and / or series circuits; Preferably, the edge of the opening groove is provided with a sealing groove and / or a sealing device, and the power module is sealed to the opening groove.

3. The motor controller assembly as described in claim 1, characterized in that, The power module assembly also includes: A plurality of AC busbars, each of the AC busbars being electrically connected to an AC terminal of a corresponding power module; A plurality of current sensors, wherein the current sensors are used to detect the phase current and / or the branch current of the power module; A driver board assembly, wherein the driver board assembly is electrically connected to a plurality of the power modules; Each of the power modules is respectively provided with a set of AC busbars and a current sensor, thereby forming a power module unit, and the power module assembly includes a plurality of the power module units; Preferably, the current sensor is disposed on the connection path between the AC terminal of the power module and the AC busbar and / or with the external three-phase connector.

4. The motor controller assembly as claimed in claim 1, characterized in that, The DC bus assembly includes a positive DC bus and a negative DC bus, and an insulating layer is sandwiched between the positive DC bus and the negative DC bus to form a stacked bus structure.

5. The motor controller assembly as claimed in claim 1, characterized in that, The capacitor assembly is fixed to the controller base plate by a bracket, and the bracket has a vibration-resistant reinforcement structure and / or a terminal insulation protection structure. And / or, the capacitor assembly is connected to the power bus corresponding to the upper power module group and the power bus corresponding to the lower power module group through the DC bus assembly, thereby providing DC support to the upper power module group and the lower power module group simultaneously.

6. The motor controller assembly as claimed in claim 1, characterized in that, The motor controller assembly further includes several three-phase busbars, each of which is electrically connected to the AC side of the power module assembly via an AC busbar. Preferably, several of the three-phase busbars are connected to power modules of different heights by means of staggered lengths.

7. The motor controller assembly as described in any one of claims 1 to 6, characterized in that, The controller base plate on the front side of the capacitor assembly has a reserved installation area for installing the generator controller assembly and / or DC / DC controller and / or other electric drive controller modules.

8. An electric drive assembly, the electric drive assembly comprising a motor and a motor controller assembly for controlling the motor, characterized in that, The motor controller assembly is the motor controller assembly described in any one of claims 1 to 7; The motor controller assembly is installed below or to the side of the motor and forms a longitudinally stacked integrated structure with the motor; The three-phase winding terminals of the motor are located at the rear end and / or the upper rear region of the motor. The three-phase winding terminals of the motor are rigidly electrically connected to the AC side of the power module component of the motor controller assembly through several three-phase busbars, thereby shortening the three-phase power circuit and reducing stray inductance.

9. The electric drive assembly as described in claim 8, characterized in that, The motor controller assembly has a mounting area corresponding to the rear end and / or upper rear region of the motor, and the three-phase busbar extends and bends in the axial and / or radial directions within the mounting area to be electrically connected to the corresponding three-phase winding terminals respectively. Preferably, a support structure is provided on the three-phase busbar to improve its mechanical strength under vibration and to ensure the electrical clearance between phases and to ground.

10. A hybrid powertrain, the hybrid powertrain comprising an engine and an electric drive assembly, characterized in that, The electric drive assembly is the electric drive assembly described in claim 8 or 9.

Images