A motor controller, drive assembly, and vehicle
Patent Information
- Application Number
- CN202510302323.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-03-13
- Publication Date
- 2026-09-15
Smart Images
Figure CN122764086A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of motor technology, and more particularly to a motor controller, drive assembly, and vehicle. Background Technology
[0002] With the development of technology and the public's demand for a better life, electric vehicles are becoming more closely connected with people, and therefore the demand for controllers inside electric vehicles is gradually increasing.
[0003] In related technologies, the water channel cooling function of motor controllers is limited. Each power module and capacitor requires a separate water channel for cooling. The power module includes DC electrical components and AC electrical components. In order to ensure the cooling effect, the DC electrical components and AC electrical components are arranged in a cross manner, which directly affects each other and results in low cooling efficiency. Summary of the Invention
[0004] This application provides a motor controller, a drive assembly, and a vehicle, aiming to solve the technical problems of electromagnetic interference and low heat dissipation efficiency caused by the cross-layout of DC and AC components in motor controllers in related technologies.
[0005] To achieve the above objectives, according to a first aspect of this application, a motor controller is provided, comprising:
[0006] First cooling plate; and,
[0007] A DC component and an AC component are respectively mounted on the first cooling plate, and the first cooling plate is located between the DC component and the AC component;
[0008] The first cooling plate is configured to isolate electromagnetic signals between the DC component and the AC component.
[0009] In some embodiments, the first cooling plate is made of metal.
[0010] In some embodiments, the first cooling plate includes a first mounting surface and a second mounting surface disposed opposite to each other along a first direction;
[0011] The AC component is mounted on the first mounting surface, and the DC component is mounted on the second mounting surface.
[0012] In some embodiments, the DC component includes a first component, which includes at least one of a fuse component, an inductor component, and a filter component.
[0013] In some embodiments, the DC component further includes a second component, which includes at least one of a fuse component, an inductor component, and a filter component, and the second component is different from the first component.
[0014] In some embodiments, the first component has a first connecting portion on the side closer to the second component;
[0015] The second component has a second connection portion on the side near the first component, and the second connection portion is electrically connected to the first connection portion.
[0016] In some embodiments, the first cooling plate includes a first cooling section, the first cooling section having a first liquid inlet;
[0017] The first component includes a safety assembly, which is mounted on the first cooling section.
[0018] In some embodiments, the first cooling plate further includes a second cooling section, which is in communication with the first cooling section;
[0019] The second component also includes an inductor assembly, which is mounted on the second cooling section.
[0020] In some embodiments, the first cooling plate further includes a third cooling section, which is in communication with the second cooling section;
[0021] The second component also includes a filter assembly, which is mounted on the third cooling section.
[0022] In some embodiments, the motor controller further includes a connector extending along a first direction, the connector having a DC interface facing a first cooling plate, the DC interface being for insertion of the DC component.
[0023] In some embodiments, the AC component includes an IGBT component mounted on the second mounting surface of the first cooling plate.
[0024] In some embodiments, the AC component further includes a heat-conducting element, one end of which is disposed on the IGBT component, and the IGBT component is mounted on the first cooling plate via the heat-conducting element.
[0025] In some embodiments, a receiving groove is formed on the first cooling plate, and the end of the heat-conducting element away from the IGBT assembly is received in the receiving groove.
[0026] In some embodiments, the AC component further includes a Hall effect sensor mounted on the first cooling plate, the Hall effect sensor being disposed on one side of the IGBT component and electrically connected to the IGBT component.
[0027] In some embodiments, the AC component further includes a three-phase component mounted on the first cooling plate, the three-phase component being disposed on the side of the Hall component away from the IGBT component and electrically connected to the IGBT component.
[0028] In some embodiments, the IGBT assembly includes a third connection portion that passes through the Hall element and is connected to the three-phase assembly.
[0029] In some embodiments, the motor controller further includes a second cooling plate disposed on one side of the first cooling plate along a third direction, the second cooling plate cooperating with the first cooling plate to cool the DC component and the AC component;
[0030] Wherein, the third direction intersects with the first direction.
[0031] In some embodiments, the motor controller further includes a capacitor assembly configured to be mounted on the side of the second cooling plate facing the first cooling plate.
[0032] In some embodiments, the motor controller further includes two third cooling plates, which are disposed on opposite sides of the first cooling plate along a second direction and are both connected to the first cooling plate, wherein one of the third cooling plates is also connected to the second cooling plate;
[0033] Wherein, the second direction intersects with the first direction and also intersects with the third direction.
[0034] According to a second aspect of this application, a drive assembly is provided, including the motor controller described above.
[0035] In some embodiments, the drive assembly further includes a drive motor, which is disposed below the motor controller in a first direction such that the drive motor is electrically connected to the AC component.
[0036] In some embodiments, a first cooling channel is formed in the first cooling plate, and a second cooling channel is formed in the drive motor. The first cooling channel and the second cooling channel are connected so that the cooling medium flows from the second cooling channel to the first cooling channel.
[0037] According to a third aspect of this application, a vehicle is also provided, including the aforementioned motor controller or the aforementioned drive assembly.
[0038] Beneficial effects:
[0039] In the technical solution of this application, the motor controller includes an AC component and a DC component. A first cooling plate is located between the DC component and the AC component. The first cooling plate can isolate the electromagnetic signals between the DC component and the AC component, avoid electromagnetic interference between them, and improve the electromagnetic compatibility inside the motor controller. At the same time, the AC component and the DC component are mounted on the first cooling plate, and the first cooling plate can directly cool the AC component and the DC component, resulting in better heat dissipation.
[0040] Other features and advantages of this application will be described in detail in the following detailed description section. Attached Figure Description
[0041] 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.
[0042] 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.
[0043] Figure 1 These are schematic diagrams of the structure of some embodiments of the drive assembly provided in this application;
[0044] Figure 2 These are schematic diagrams of some embodiments of the first cooling plate, second cooling plate, and third cooling plate provided in this application;
[0045] Figure 3 yes Figure 2 Another structural diagram from a different perspective;
[0046] Figure 4 This is a schematic diagram of the structure of the DC component provided in this application (including the first cooling plate);
[0047] Figure 5 yes Figure 4 Enlarged diagram of A in the middle;
[0048] Figure 6 yes Figure 4 Schematic diagrams of some embodiments of the filtering component;
[0049] Figure 7 yes Figure 6 A full sectional view;
[0050] Figure 8 yes Figure 6 Another structural diagram from a different perspective;
[0051] Figure 9 yes Figure 6 Another structural diagram from a different perspective;
[0052] Figure 10 yes Figure 6 Another full cross-section diagram;
[0053] Figure 11 yes Figure 6 Structural diagrams of some embodiments of the inductor component;
[0054] Figure 12 yes Figure 6 Structural diagrams of some embodiments of the insurance component;
[0055] Figure 13 yes Figure 2 Another structural diagram from a different perspective;
[0056] Figure 14 This is a schematic diagram of the structure of the communication component provided in this application;
[0057] Figure 15 These are schematic diagrams of some embodiments of the capacitor assembly provided in this application;
[0058] Figure 16 yes Figure 15 Another structural diagram from a different perspective;
[0059] Figure 17 This is a full cross-sectional schematic diagram of the capacitor assembly and IGBT assembly provided in this application.
[0060] Figure 18 This is a front view of the capacitor assembly and IGBT assembly provided in this application in combination;
[0061] Figure 19 yes Figure 1 A structural diagram from another perspective.
[0062] Explanation of reference numerals in the attached figures:
[0063] 1000, Drive assembly; 100, Motor controller; 10e, First cooling plate; 11e, First mounting surface; 12e, Second mounting surface; 13e, Receiving groove; 14e, First cooling section; 15e, Second cooling section; 16e, Third cooling section; 20e, DC component; 21e, First component; 211e, First connection section; 22e, Second component; 221e, Second connection section; 23e, Fuse assembly; 24e, Inductor assembly; 25e, Filter assembly; 30e, AC component; 31e, IGBT assembly; 311e, Third connection section; 32e, Heat-conducting component; 33e, Hall effect sensor assembly; 34e, Three-phase assembly; 35e, Capacitor assembly; 36e, Drive board; 37e, Control board; 38e, Shielding component; 40e, Second cooling plate; 50e, Third cooling plate; 200, Drive motor; 201, Filter housing; 202, Filter cover plate; 203, Positive DC interface output copper busbar; 204, Negative DC interface output copper busbar; 205, Positive DC copper busbar; 206, Negative DC copper busbar; 207, Left drive N-line copper busbar; 208, Right drive N-line copper busbar; 209, Anti-contact cap; 210, Sealing buckle; 211, First magnetic ring; 212, Second magnetic ring; 213, First capacitor sub-assembly; 214, Second capacitor sub-assembly; 215, First grounding copper busbar; 216, Second grounding copper busbar; 217, Third grounding copper busbar; 218, First metal shielding plate; 219, Second metal shielding plate; 220 1. First small copper busbar; 221. Second small copper busbar; 222. Third small copper busbar; 223. First filter board; 224. Second filter board; 2a. First cavity; 2b. Second cavity; 2c. Third cavity; 2d. Fourth cavity; 301. Inductor housing; 302. Inductor input copper busbar; 303. First inductor output copper busbar; 304. Second inductor output copper busbar; 305. Inductor copper busbar fixing housing; 306. First coil; 307. Second coil; 401. Fuse base; 402. First DC fuse output copper busbar; 403. Second DC fuse output copper busbar; 4a. First groove; 4b. Wire harness fixing slot; 5. Excitation fuse; 6. Adapter board; 6a. Second connector; 701. Capacitor housing; 702. 703. First positive capacitor input copper busbar; 704. Second positive capacitor input copper busbar; 705. Negative capacitor input copper busbar; 706. Left drive positive capacitor output busbar; 707. Left drive negative capacitor output busbar; 708. Right drive positive capacitor output busbar; 709. Right drive negative capacitor output busbar; 710. High voltage sampling; 8a. Isolation plate; 8b. Left drive capacitor and IGBT adapter copper busbar; 801. Insulating coating layer; 11. Floating connector control terminal; 12. Floating connector drive terminal; 18. Low voltage magnetic ring; 19. Motor terminal block; 20. Three-phase explosion fuse; 22. Thermal pad; 21. DC interface; 21a. DC interface slot; 2001. First opening;2002, the second opening. Detailed Implementation
[0064] 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.
[0065] In related technologies, the water channel cooling function of motor controllers is limited. Each power module and capacitor requires a separate water channel for cooling. The power module includes DC electrical components and AC electrical components. In order to ensure the cooling effect, the DC electrical components and AC electrical components are arranged in a cross manner, which directly affects each other and results in low cooling efficiency.
[0066] In view of this, this application proposes a drive assembly 1000, Figures 1 to 19 This is a schematic diagram of the structure of one embodiment of the drive assembly 1000 provided in this application.
[0067] Please see Figure 1 The drive assembly 1000 includes a motor controller 100 and a drive motor 200. The drive motor 200 includes a housing with a mounting portion formed on the housing, and the motor controller 100 is disposed in the mounting portion.
[0068] According to the first aspect of this application, referring to Figure 1 and Figure 2 This application provides a motor controller 100, which includes a first cooling plate 10e, a DC component 20e, and an AC component 30e. The DC component 20e and the AC component 30e are respectively mounted on the first cooling plate 10e, and the first cooling plate 10e is located between the DC component 20e and the AC component 30e. The first cooling plate 10e is configured to isolate electromagnetic signals between the DC component 20e and the AC component 30e.
[0069] In the technical solution of this application, the motor controller 100 includes an AC component 30e and a DC component 20e. The first cooling plate 10e is located between the DC component 20e and the AC component 30e. The first cooling plate can isolate the electromagnetic signals between the DC component 20e and the AC component 30e, avoid electromagnetic interference between them, and improve the electromagnetic compatibility inside the motor controller 100. At the same time, the AC component 30e and the DC component 20e are mounted on the first cooling plate 10e, and the first cooling plate 10e can directly cool the AC component 30e and the DC component 20e, resulting in better heat dissipation.
[0070] In this embodiment, the AC component 30e and the DC component 20e are directly integrated on the first cooling plate 10e. The first cooling plate 10e can also provide support while cooling, eliminating the need for additional support structures, improving space utilization, saving parts, and reducing costs.
[0071] The specific material of the first cooling plate 10e is not limited, as long as it can achieve electromagnetic shielding. In some embodiments, the first cooling plate 10e is made of metal, that is, the first cooling plate 10e is a metal plate. More specifically, the material of the first cooling plate 10e can be cast iron, aluminum alloy, copper alloy, or other metals. In other embodiments, the first cooling plate 10e can also be a plastic plate, with a coating on the outer surface of the plastic plate to provide electromagnetic shielding, thereby isolating the electromagnetic signals between the DC component 20e and the AC component 30e. Specifically, the coating can be an iron alloy coating, a copper alloy coating, an aluminum alloy coating, etc.
[0072] Please see Figure 2 ,by Figure 2 Taking the first direction as an example, the first direction intersects with the second direction, the first direction intersects with the third direction, and the second direction intersects with the third direction. The first direction, the second direction, and the third direction are located in different planes. The included angle between any two of the first direction, the second direction, and the third direction is not limited and can be 60°, 80°, 85°, 90°, 95°, 100°, or other angles. In the following embodiments, the included angle between any two of the first direction, the second direction, and the third direction is 90°, that is, some embodiments of this application are explained by establishing a spatial rectangular coordinate system using the first direction, the second direction, and the third direction. It should be emphasized that the included angle between any two of the first direction, the second direction, and the third direction is 90° and does not constitute a limitation on the following embodiments of this application. In this embodiment, the first direction is the thickness direction of the first cooling plate 10e, the second direction is the width direction of the first cooling plate 10e, and the third direction is the length direction of the first cooling plate 10e.
[0073] Please see Figure 2 The first cooling plate 10e includes a first mounting surface 11e and a second mounting surface 12e arranged opposite to each other along a first direction. The mounting method of the AC component 30e and the DC component 20e is not limited. For example, the AC component 30e can be mounted on the first mounting surface 11e and the DC component 20e can be mounted on the second mounting surface 12e; alternatively, the AC component 30e can be mounted on the second mounting surface 12e and the DC component 20e can be mounted on the first mounting surface 11e. The appropriate method can be selected based on the actual situation.
[0074] In this embodiment, the motor controller 100 is mounted on the drive motor 200. During installation, the first mounting surface 11e of the first cooling plate 10e faces the drive motor 200. The drive motor 200 also generates electromagnetic signals during operation, which can interfere with the DC component 20e. Therefore, to improve the electromagnetic compatibility of the entire drive assembly 1000, the AC component 30e is mounted on the first mounting surface 11e, and the DC component 20e is mounted on the second mounting surface 12e. The first cooling plate 10e not only isolates the electromagnetic signals from the AC component 30e but also isolates the electromagnetic signals from the drive motor 200, thereby improving the electromagnetic compatibility within the drive assembly 1000.
[0075] Please see Figure 3 and Figure 4 The DC component 20e includes a first component 21e and a second component 22e. The first component 21e and the second component 22e are disposed on the second mounting surface 12e of the first cooling plate 10e. The first component 21e and the second component 22e are of different types. Considering the space utilization, the first component 21e and the second component 22e are spaced apart along a third direction. The first component 21e is electrically connected to the second component 22e.
[0076] In some embodiments, please refer to Figure 4 The first component 21e can be a fuse component 23e, an inductor component 24e, or a filter component 25e. The second component 22e can be a fuse component 23e, an inductor component 24e, or a filter component 25e, depending on the actual situation.
[0077] Specifically, the connection method of the first component 21e and the second component 22e is not limited and can be selected according to the actual situation. In some embodiments, please refer to... Figure 4 and Figure 5 The first component 21e includes a first body and a first connecting portion 211e, the first connecting portion 211e being disposed on the side of the first body near the second component 22e; the second component 22e includes a second body and a second connecting portion 221e, the second connecting portion 221e being disposed on the side of the second body near the first component 21e, and the second connecting portion 221e being electrically connected to the first connecting portion 211e, so that the first component 21e and the second component 22e are electrically connected. More specifically, to ensure the stability of the connection, the first connecting portion 211e and the second connecting portion 221e overlap in a first direction; furthermore, the first connecting portion 211e and the second connecting portion 221e are arranged overlapping in the first direction, which can improve space utilization and save space.
[0078] Please see Figure 3The first cooling section 14e includes a first cooling section 14e, a second cooling section 15e and a third cooling section 16e arranged sequentially along a third direction. The first cooling section 14e is connected to the second cooling section 15e and the second cooling section 15e is connected to the third cooling section 16e.
[0079] Please see Figure 3 and Figure 4 In some embodiments, the fuse component 23e is highly sensitive to temperature, therefore it needs to be placed in a low-temperature location. Since the temperature decreases at the point where the cooling medium first passes through the first cooling plate 10e during the cooling process, the fuse component 23e needs to be installed at the location on the first cooling plate 10e where the cooling medium first flows. Specifically, the first cooling section 14e has a first liquid inlet, through which the cooling medium enters the first cooling section 14e. The fuse component 23e is installed on the first cooling section 14e and close to the first liquid inlet; this ensures that the fuse component 23e is kept at a low temperature, guaranteeing its normal operation.
[0080] Please continue reading. Figure 3 and Figure 4 The second component 22e also includes an inductor assembly 24e, which is located on the third-direction side of the fuse assembly 23e and is electrically connected to the fuse assembly 23e. The inductor assembly 24e is mounted on the second cooling section 15e. This design helps improve cooling efficiency, ensuring that the inductor assembly 24e can effectively dissipate heat during operation, thereby improving the overall performance and reliability of the motor controller 100.
[0081] In some embodiments, please refer to Figure 3 and Figure 4 The second component 22e also includes a filter assembly 25e, which is located on the side of the inductor assembly 24e facing away from the fuse assembly 23e. The filter assembly 25e is electrically connected to the inductor assembly 24e and is mounted on the third cooling section 16e. This design helps improve cooling efficiency and ensures that the filter assembly 25e can effectively dissipate heat during operation, thereby improving the overall performance and reliability of the motor controller 100.
[0082] In some embodiments, the motor controller 100 further includes a connector extending along a first direction, the connector having a DC interface 21 facing a second mounting surface 12e of the first cooling plate 10e, and the connector engaging with the DC component 20e via the DC interface 21.
[0083] Please see Figure 6 , Figure 7 , Figure 8 and Figure 9In some embodiments, the filter assembly 25e includes a filter housing 201, a filter cover plate 202, a positive DC interface output copper busbar 203, a negative DC interface output copper busbar 204, a positive DC copper busbar 205, a negative DC copper busbar 206, a left-drive N-line copper busbar 207, a right-drive N-line copper busbar 208, an anti-touch cap 209, a sealing buckle 210, a first magnetic ring 211, a second magnetic ring 212, a first capacitor sub-assembly 213, a second capacitor sub-assembly 214, a first grounding copper busbar 215, a second grounding copper busbar 216, a third grounding copper busbar 217, a first metal shielding plate 218, a second metal shielding plate 219, a first small copper busbar 220, a second small copper busbar 221, a third small copper busbar 222, a first filter plate 223, and a second filter plate 224.
[0084] Please continue reading. Figure 6 and Figure 7 In some embodiments, in the first direction, the DC interface 21 is fixedly connected to the positive DC interface 21 output copper busbar 203 and the negative DC interface output copper busbar 204 via the DC interface slot 21a. The positive DC interface output copper busbar 203 and the negative DC interface output copper busbar 204 are injection molded integrally with the filter housing 201.
[0085] In some embodiments, please continue reading Figure 7 , Figure 8 , Figure 9 and Figure 10 In the second direction, one end of the positive DC interface output copper busbar 203 is welded to the inductor input copper busbar 302 of the inductor assembly 24e. In the second direction, the other end of the negative DC interface output copper busbar 204 is welded to the negative capacitor input copper busbar 704 of the capacitor assembly 35e. Compared to screw connections, welding provides a more stable connection, reduces the number of components, decreases impedance, and improves current utilization.
[0086] Please continue reading. Figures 6 to 9In some embodiments, the positive DC busbar 205 and the negative DC busbar 206 are inserted into the copper busbar routing groove on the filter cover plate 202. The positive DC busbar 205 and the negative DC busbar 206 are bolted to the filter housing 201 at one end in the third direction, thus enabling connection to the external charging gun. The other end of the positive DC busbar 205 is welded below the connection point between the positive DC interface output copper busbar 203 and the DC interface. The other end of the negative DC busbar 206 is welded below the connection point between the negative DC interface output copper busbar 204 and the DC interface 21. In the first direction, the left drive N-line copper busbar 207 and the right drive N-line copper busbar 208 pass through the first magnetic ring 211 and the second magnetic ring 212 and connect to the terminal block of the drive motor 200. The left drive N-line copper busbar 207 serves a self-heating function, and the right drive N-line copper busbar 208 serves to boost the motor voltage. Anti-contact caps 209 are installed on the top of the copper busbars 203 (positive DC interface output), 204 (negative DC interface output), 207 (left drive N line copper busbar), and 208 (right drive N line copper busbar) that connect to the DC interface 21. These caps are then bonded to the copper busbars. The tilt angle at the top of the anti-contact caps 209 serves to guide the copper busbars and prevent them from being scratched by contact.
[0087] Compared to the bolt-fixing method used in related technologies, this embodiment directly inserts the copper busbars (i.e., positive DC interface output copper busbar 203, negative DC interface output copper busbar 204, left drive N-line copper busbar 207, and right drive N-line copper busbar 208) into the connector slots. Each copper busbar has an anti-contact cap 209 installed at its top end where it connects to the DC interface 21, which adheres to the copper busbar. The tilt angle of the top end of the anti-contact cap 209 serves to guide and prevent scratches from the copper busbars. The plastic housing of the connector has threaded holes and is fastened to the motor housing with bolts. The copper busbars of the connector do not need to be fixed with bolts, thus improving space utilization.
[0088] Please see Figure 10 The filter housing 201 has a first main chamber, which includes a first cavity 2a, a second cavity 2b, a third cavity 2c, and a fourth cavity 2d.
[0089] Please continue reading. Figure 10, in some embodiments, the first magnetic ring 211 is placed in the first cavity 2a, and the filter cover plate 202 is fixedly closed with the filter housing 201 through the clamping groove at the opening edge of the first cavity 2a. A square-frame-shaped copper bar routing clamping groove protrudes from the plane of the filter cover plate 202, which together with the clamping groove of the filter housing 201 forms a routing path for the positive DC copper bar 205 and the negative DC copper bar 206, functioning to shield the large current on the positive DC copper bar 205 and the negative DC copper bar 206. In addition, since one end of the positive DC copper bar 205 and the negative DC copper bar 206 is fastened to the filter housing 201 and the other end is welded, the clamping groove can also prevent large position deviation of the copper bars to facilitate welding. That is, when tightening the bolt at one end of the copper bars, a torsional force will be applied, which causes a certain angular deviation of the positive DC copper bar 205 and the negative DC copper bar 206, such that the welded end face of the other end cannot fit against the positive DC interface output copper bar 203 and the negative DC interface output copper bar 204.
[0090] For further reference, please see Figure 10 , in some embodiments, the first capacitive subassembly 213 is placed inside the second cavity 2b, and partitions and reinforcing ribs are provided inside the second cavity 2b for placing capacitor cores and performing glue pouring. Pins of four Y-capacitor cores are connected to the upper first filter board 223, and one end of four additional first small copper bars 220 are respectively welded to the surfaces of the left-drive N-line copper bar 207, the right-drive N-line copper bar 208, the positive DC interface output copper bar 203 and the negative DC interface output copper bar 204. The other end of the first small copper bars 220 is welded to the first filter board 223 and is injection-molded and fixed in the filter housing 201, and the first grounding copper bar 215 on the first filter board 223 is bent down and fixed together to the electronic control water channel via a nut in the housing.
[0091] For further reference, please see Figure 10 , in some embodiments, the third cavity 2c is a hollow-square-shaped space, the second magnetic ring 212 is divided into a C-shaped part and a strip-shaped part, one part is inserted through the first opening 2001 of the filter assembly 25e, and the other part of the second magnetic ring 212 strip is inserted through the second opening 2002 of the filter assembly 25e. Since the material of the second magnetic ring 212 is ferrite which has magnetism, the two parts of the second magnetic ring 212 form a closed magnetic ring circuit, and the protruding part on the side edge of the second opening 2002 is clamped through the square hole on the magnetic ring buckle, so as to enclose the second magnetic ring 212 in the third cavity 2c.
[0092] For further reference, please see Figure 10In some embodiments, the fourth cavity 2d is used to house the second capacitor sub-assembly 214. Similarly, the pins of the capacitor core of the second capacitor sub-assembly 214 are connected to the second filter plate 224. The second grounding copper busbar 216 and the third grounding copper busbar 217 are injection molded into the filter housing 201. One end of the second grounding copper busbar 216 and the third grounding copper busbar 217 is fastened together with the filter housing 201 to the first cooling plate 10e, and the other end of the second grounding copper busbar 216 and the third grounding copper busbar 217 is welded to the second filter plate 224. The positive DC interface output copper busbar 203 and the negative DC interface output copper busbar 204 are welded to the second small copper busbar 221 and the third small copper busbar 222, respectively. The other end of the second small copper busbar 221 and the third small copper busbar 222 is welded to the second filter plate 224, which serves to connect the capacitor cores on both sides of the magnetic ring. Since the partition of the fourth cavity 2d is higher than the internal components, all the internal components of the fourth cavity 2d are then potted with glue to isolate the second filter plate 224 from the first cooling plate 10e below.
[0093] In some embodiments, the filter assembly 25e also incorporates copper busbar heat dissipation. The left-drive N-line copper busbar 207 and the right-drive N-line copper busbar 208 are curved in the middle, with the protruding arc-shaped portion of the copper busbar protruding outside the filter assembly 25e housing and contacting the thermal pad 22. The thermal pad 22 then contacts the boss on the electronically controlled water channel plate, thus dissipating heat from the left-drive N-line copper busbar 207 and the right-drive N-line copper busbar 208 and improving their current-carrying capacity. The first metal shielding plate 218 and the second metal shielding plate 219 in the filter assembly 25e are injection molded into the filter housing 201. Each of the first metal shielding plate 218 and the second metal shielding plate 219 extends a grounding terminal and is fastened to the injection-molded parts with bolts. This reduces mutual interference between the copper busbars and effectively improves the electromagnetic compatibility within the motor controller 100.
[0094] Please see Figure 11 In some embodiments, the inductor assembly 24e includes an inductor housing 301, an inductor input copper busbar 302, a first inductor output copper busbar 303, a second inductor output copper busbar 304, an inductor copper busbar fixing housing 305, a first coil 306, and a second coil 307.
[0095] For details, please continue reading Figure 11The inductor housing 301 has a second main chamber, which includes two inductor sub-cavities. These sub-cavities house the first coil 306 and the second coil 307, respectively. After placement, the two sub-cavities are sealed with potting compound. One end of the inductor input copper busbar 302 is welded to the positive DC interface output copper busbar 203. The other end of the inductor input copper busbar 302 branches into two inductor copper busbar connectors, which are welded to the input terminals of one end of the first coil 306 and the second coil 307, respectively. The output terminals of the other ends of the first coil 306 and the second coil 307 are welded to the first inductor output copper busbar 303 and the second inductor output copper busbar 304, respectively. The inductor input copper busbar 302, the first inductor output copper busbar 303, and the second inductor output copper busbar 304 are injection molded together with the inductor copper busbar fixing housing 305 and then bonded to the potting surface of the inductor housing 301, completing the assembly of the inductor assembly 24e. The inductor housing 301 is divided into two inductor sub-cavities, allowing two sets of inductor elements to be placed inside, with the electronically controlled DC positive current flowing to the left and right drive components respectively. Integrating the two inductors into a single housing effectively improves space utilization.
[0096] Please see Figure 12 In some embodiments, the fuse assembly 23e includes a fuse base 401, a first DC fuse output copper busbar 402, a second DC fuse output copper busbar 403, an excitation fuse 5, an adapter board 6, and a second connector 6a.
[0097] For details, please continue reading Figure 12 The fuse base 401 is fixed to the first cooling plate 10e. Two excitation fuses 5 are placed in the two first grooves 4a of the fuse base 401, respectively. One end of the first inductor output copper busbar 303 and the second inductor output copper busbar 304 are connected to one end of the two excitation fuses 5 via connecting copper busbars and fixed to the fuse base 401 with bolts. The first DC fuse output copper busbar 402 and the second DC fuse output copper busbar 403 are nested in a rivet nut. The first DC fuse output copper busbar 402 and the second DC fuse output copper busbar 403, along with the rivet nut, are injection molded into the housing of the DC fuse. The other ends of the first DC fuse output copper busbar 402 and the second DC fuse output copper busbar 403 are welded to the first positive capacitor input copper busbar 702 and the second positive capacitor input copper busbar 703, respectively. The fuse base 401 has four fixing points, and the four fixing holes of the adapter plate 6 are fastened with bolts. A wire harness fixing slot 4b is opened on the side of the safety base 401 to fix the wire harness protruding from the second connector 6a. No separate fixing clip is needed, saving cost and space.
[0098] Please see Figure 13 and Figure 14The AC component 30e is mounted on the second mounting surface 12e of the first cooling plate 10e. Specifically, the AC component 30e includes an IGBT component 31e, a Hall component 33e, a three-phase component 34e, a driver board 36e, a control board 37e, and a shield 38e.
[0099] It should be noted that the number of IGBT components 31e, Hall effect components 33e, three-phase components 34e, driver boards 36e, control boards 37e, and shielding components 38e is not limited and can be selected according to the actual situation. The following will describe the connection and positional relationship between AC components 30e as having two IGBT components 31e, two Hall effect components 33e, two three-phase components 34e, two driver boards 36e, two control boards 37e, and one shielding component 38e.
[0100] Please see Figure 14 , Figure 15 and Figure 16 The AC component 30e also includes a capacitor component 35e, which is located on the side of the IGBT component 31e opposite to the Hall component 33e, and is electrically connected to the IGBT component 31e. The capacitor component 35e includes a capacitor housing 701, a first positive capacitor input copper busbar 702, a second positive capacitor input copper busbar 703, a negative capacitor input copper busbar 704, a left-drive positive capacitor output busbar 705, a left-drive negative capacitor output busbar 706, a right-drive positive capacitor output busbar 707, a right-drive negative capacitor output busbar 708, a high-voltage sampling 709, and an isolation plate 710.
[0101] Please continue reading. Figure 15 and Figure 16The first positive capacitor input copper busbar 702 and the second positive capacitor input copper busbar 703 are disposed inside the capacitor housing 701, which is filled with epoxy resin potting compound. One end of the first positive capacitor input copper busbar 702 and the second positive capacitor input copper busbar 703 extends out of the capacitor housing 701, and the overlapping surface of the extended portion is bent 180° so that it is tightly attached to the capacitor housing 701. The first DC fuse output copper busbar 402 and the second DC fuse output copper busbar 403 of the fuse base 401 are respectively welded to the first positive capacitor input copper busbar 702 and the second positive capacitor input copper busbar 703, and the same applies to the negative capacitor input copper busbar 704. Since a single capacitor housing 701 integrates two capacitor cores (left and right drives), resulting in a relatively large capacitor volume, a hole is drilled in the horizontal direction of the first cooling plate 10e (i.e., the plane enclosed by the second and third directions). The copper busbar above the first cooling plate 10e of the capacitor assembly 35e is connected to the DC terminal, and the copper busbar below the first cooling plate 10e of the capacitor assembly 35e is connected to the AC terminal. The left drive positive capacitor output busbar 705 and the right drive positive capacitor output busbar 707 are soldered to the positive input terminal of the IGBT assembly 31e. The left drive positive capacitor output busbar 705 and the right drive positive capacitor output busbar 707 branch into three terminals on the side that overlaps with the IGBT assembly 31e, allowing DC current to flow to the three-phase AC side. The left drive capacitor negative output busbar and the right drive capacitor negative output busbar overlap with the copper busbar 8bb of the right drive capacitor and IGBT adapter, respectively. A plastic isolation plate 710 is used to increase the electrical clearance between the positive and negative capacitor output buses. The bottom of capacitor assembly 35e has two positive high-voltage sampling posts 709 and one negative high-voltage sampling post 709. The outer walls of the positive and negative high-voltage sampling posts 709 are made of plastic shells, which are bonded to the capacitor shell 701 and serve as insulation. Inside the plastic shells are copper posts with threads on their inner walls. The control board 37e is fixed to the three high-voltage sampling posts 709 of the capacitor using bolts. Integrating the two sub-capacitors into a single capacitor shell 701 effectively improves space utilization.
[0102] Please see Figure 14 and Figure 17The AC component 30e includes an IGBT component 31e (Insulated Gate Bipolar Transistor), which is mounted on the second mounting surface 12e of the first cooling plate 10e. In this embodiment, two IGBT components 31e are provided, spaced apart along a third direction, with the two IGBT components 31e located on the left and the right, respectively. After the capacitor assembly 35e is installed with the IGBT assembly 31e on the left and the IGBT assembly 31e on the right, the insulating coating layer 801 is installed first. Then, the left drive capacitor and IGBT adapter copper busbar 8a and the right drive capacitor and IGBT adapter copper busbar 8b are soldered to the negative capacitor output busbar and the negative terminals of the left drive and right drive IGBTs, respectively. The middle part of the left drive capacitor and IGBT adapter copper busbar 8a and the right drive capacitor and IGBT adapter copper busbar 8b is bent and chamfered. This can improve the copper busbar's resistance to deformation and increase the gap between the copper busbars, making it easier to place the insulating coating layer 801 in the middle.
[0103] Please continue reading. Figure 14 and Figure 16 The AC component 30e also includes a heat-conducting element 32e, one end of which is disposed on the IGBT component 31e. The IGBT component 31e is mounted on the first cooling plate 10e via the heat-conducting element 32e. In this embodiment, the heat-conducting element 32e includes multiple heat-dissipating aluminum pins disposed on the side of the IGBT component 31e away from the drive plate 36e. The heat-conducting element 32e absorbs the heat generated by the IGBT component 31e and then transfers the heat to the first cooling plate 10e, thereby improving cooling efficiency.
[0104] Furthermore, in order to improve space utilization, a receiving groove 13e is formed on the first cooling plate 10e, and the end of the heat-conducting element 32e away from the IGBT assembly 31e is received in the receiving groove 13e.
[0105] Please see Figure 14 A Hall effect sensor 33e is mounted on the first cooling plate 10e, located on one side of the IGBT assembly 31e, and electrically connected to it. A three-phase assembly 34e is mounted on the first cooling plate 10e, located on the side of the Hall effect sensor 33e opposite to the IGBT assembly 31e, and electrically connected to it. The IGBT assembly 31e includes a third connection portion 311e, which passes through the Hall effect sensor 33e and connects to the three-phase assembly 34e.
[0106] Please continue reading. Figure 14In some embodiments, the drive board 36e is located on the side of the IGBT assembly 31e facing away from the first cooling plate 10e, and the drive board 36e is electrically connected to the IGBT assembly 31e. The IGBT assembly 31e is directly connected to the drive board 36e, thereby allowing the IGBT assembly 31e to be integrated onto the drive board 36e. This reduces the number of adapter structures between the IGBT assembly 31e and the drive board 36e, and also fixes the IGBT assembly 31e and the drive board 36e to each other, improving structural stability and making the internal structure of the motor controller more compact. This improves the integration of the motor controller 100, optimizes the space of the motor controller 100, and contributes to the lightweighting of the motor controller 100.
[0107] Please see Figure 14 In some embodiments, the control board 37e is located on the side of the drive board 36e opposite to the IGBT assembly 31e, and the control board 37e is electrically connected to the capacitor.
[0108] Furthermore, the AC assembly 30e also includes a shield 38e, which is disposed between the drive board 36e and the control board 37e. The shield 38e is used to electrically isolate the drive board 36e and the control board 37e. In this embodiment, the side of the isolation plate 710 facing the first cooling plate 10e forms a high-voltage cavity with the first cooling plate 10e, and the side of the isolation plate 710 away from the first cooling plate 10e forms a low-voltage cavity, which can accommodate low-voltage electrical appliances. The function of the isolation plate 710 is to separate the control board 37e from the drive board 36e, thereby preventing the high-voltage part from affecting the control board 37e, thus allowing the control board 37e to operate normally.
[0109] Please continue reading. Figure 2 The cooling system of the motor controller 100 mainly consists of a first cooling plate 10e, a second cooling plate 40e, and two third cooling plates 50e. The first cooling plate 10e divides the electrical control layout space into upper, lower, rear, left, and right sides. The DC side components, including the filter component 25e, the inductor component 24e, and the fuse component 23e, are fixed on the upper part of the first cooling plate 10e. The second cooling plate 40e is used to fix the capacitor component 35e. The capacitor component 35e is located on the side of the second cooling plate 40e facing the first cooling plate 10e. This arrangement is for convenience. The capacitor component 35e is electrically connected to the DC component 20e and the AC component 30e.
[0110] Please continue reading. Figure 2 Below the first cooling plate 10e, the AC assembly 30e is fixed, including the IGBT assembly 31e, the shielding plate, the Hall effect assembly 33e, and the three-phase assembly 34e. Each of the two third cooling plates 50e is equipped with a lifting lug to facilitate automated operation on the production line. The electrically controlled water channel plate can be installed and removed through the lifting lug.
[0111] The first cooling plate 10e includes a first cooling section 14e, a second cooling section 15e, and a third cooling section 16e. The first cooling section 14e forms a first cooling cavity, the second cooling section 15e forms a second cooling cavity, and the third cooling section 16e forms a third cooling cavity. The water channel inlet of the first cooling plate 10e is located directly pressed onto the motor water channel inlet by a sealing ring. After the cooling medium enters the electronic control water channel plate from the inlet below the water channel plate, it first enters the first cooling cavity below the water channel plate through the third cooling plate 50e on the right side to cool the IGBT component 31e located on the left side. The cooling medium enters the third cooling cavity from the second cooling cavity. When passing through the second cooling cavity, it can dissipate heat for the inductor component 24e installed in the second cooling section 15e.
[0112] The cooling medium flows to the third cooling chamber. When passing through the third cooling chamber, it can dissipate heat for some of the IGBT components 31e installed in the third cooling section 16e. The bottom of the IGBT component 31e is equipped with heat dissipation aluminum pins. The heat dissipation aluminum pins conduct the heat of the IGBT component 31e to the cooling medium for cooling. The heat dissipation aluminum pins also have the function of guiding the flow.
[0113] The cooling medium then enters the third cooling plate 50e on the left side, then turns into the water channel and enters the second cooling plate 40e. Due to the larger internal space of the second cooling plate 40e, it is equipped with water channel guide ribs to prevent dead zones and slow-flow areas behind the water channel. This also facilitates better contact between the cooling medium and the inner wall of the second cooling plate 40e, improving the heat dissipation efficiency of the capacitor assembly 35e. Finally, it flows out from the outlet below the second cooling plate 40e, similar to the inlet, and is directly pressed against the motor water channel inlet by a sealing ring.
[0114] According to a second aspect of this application, a drive assembly 1000 is provided, which includes the aforementioned motor controller 100. The drive assembly 1000 possesses all the beneficial effects of the motor controller 100, which will not be elaborated further herein.
[0115] Furthermore, the drive assembly 1000 also includes a drive motor 200, which is connected to the motor controller 100.
[0116] The installation process of the drive motor 200 and the motor controller 100 is as follows:
[0117] Please see Figure 19First, install the AC component 30e, then install two three-phase components 34e. Next, pass two Hall effect sensors 33e through the third connection portion 311e of two IGBT components 31e. Then, bolt the Hall effect sensors 33e and IGBT components 31e together onto the first cooling plate 10e. The copper busbars of the IGBT components 31e are soldered onto the copper busbars of the three-phase components 34e. Next, fix two drive boards 36e above the two IGBT components 31e respectively. The pins on the IGBT components 31e are soldered to the drive boards 36e using in-line selective soldering technology. Finally, fix the capacitor component 35e onto the first cooling plate 10e and the second cooling plate 40e. The left-drive positive capacitor output busbar 705 and the right-drive positive capacitor output busbar 707 are soldered to the two IGBT components 31e. Then, the capacitor component 35e, the left-drive capacitor to IGBT adapter copper busbar 8a, and the right-drive capacitor to IGBT adapter copper busbar 8b are soldered to the left and right drive negative capacitor output busbars 708 and the negative input terminals of the IGBT components, respectively. The shielding plate is then bolted to the first cooling plate 10e, and the control board 37e is fastened to the shielding plate and bolted to the high-voltage sampling 709 of the capacitor component 35e. The floating connector drive end 12 of the drive board 36e is connected to the floating connector control end 11. At this point, the AC terminal components have been installed.
[0118] First, install the DC component 20e, then install the fuse component 23e. Align the inductor output copper busbar of the inductor component 24e with the fixing point on the fuse base 401, then install the two excitation fuses 5, and then install the adapter board 6. At the same time, after assembling and installing the filter component 25e, fix the filter component 25e on the first cooling plate 10e, weld the positive DC copper busbar 205 to the inductor input copper busbar 302, and weld the negative DC copper busbar 206 to the negative capacitor input copper busbar 704. Fix the low-voltage magnetic ring 18 to the right side of the first cooling plate 10e with bolts. At this point, the motor controller 100 device assembly is complete.
[0119] Please see Figure 19 After assembling the components of the motor controller 100, the three-phase explosion fuse 20 is installed on the motor terminal block 19, and then the motor terminal block 19 is installed on the motor housing. Subsequently, the controller is placed in the motor housing by lifting the left and right side lugs of the first cooling plate 10e. The three-phase copper busbar and the N-direction copper busbar are fixed on the motor terminal block 19. The motor end cover is installed, and the controller and motor assembly is completed. All of the above parts are fixed by bolt connection.
[0120] In some embodiments, a first cooling channel is formed within the first cooling plate 10e, and a second cooling channel is formed within the drive motor 200. The first cooling channel and the second cooling channel are connected, allowing the cooling medium to flow from the second cooling channel to the first cooling channel. Both the drive motor 200 and the controller are water-cooled. The inlet of the first cooling plate 10e is fitted with two radial sealing rings and one axial sealing ring, and the outlet is fitted with one radial sealing ring and one axial sealing ring. The first cooling plate 10e is directly aligned with the water channel opening of the drive motor 200 and pressed together by an interference fit of the sealing rings. All the openings of the water channel plate cavities are sealed with a cover plate and the electronic control water channel plate as a whole using friction welding, eliminating the need for fasteners and seals and reducing the risk of failure. This assembly method eliminates the need for separate inlet and outlet water pipes to connect the controller and the drive motor 200's water channels. The motor controller 100 and the drive motor 200 are integrated into a single water-cooled unit. One water channel of the motor controller 100 can simultaneously dissipate heat from both AC and DC side components, reducing the number of structural components, saving costs, and improving heat dissipation efficiency.
[0121] According to a third aspect of this application, a vehicle is provided that includes the aforementioned drive assembly 1000, and the vehicle has all the beneficial effects of the aforementioned drive assembly 1000, which will not be repeated here.
[0122] The vehicle may 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.
[0123] 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.
[0124] 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.
[0125] The embodiments, implementation methods, and related technical features of this application can be combined and substituted for each other without conflict.
[0126] 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 motor controller, characterized in that, include: First cooling plate; as well as, A DC component and an AC component are respectively mounted on the first cooling plate, and the first cooling plate is located between the DC component and the AC component; The first cooling plate is configured to isolate electromagnetic signals between the DC component and the AC component.
2. The motor controller according to claim 1, characterized in that, The first cooling plate is made of metal.
3. The motor controller according to claim 1, characterized in that, The first cooling plate includes a first mounting surface and a second mounting surface disposed opposite to each other along a first direction; The AC component is mounted on the first mounting surface, and the DC component is mounted on the second mounting surface.
4. The motor controller according to claim 3, characterized in that, The DC component includes a first component, which includes at least one of a fuse component, an inductor component, and a filter component.
5. The motor controller according to claim 4, characterized in that, The DC component also includes a second component, which includes at least one of a fuse component, an inductor component, and a filter component, and the second component is different from the first component.
6. The motor controller according to claim 5, characterized in that, The first component has a first connecting portion on the side closer to the second component; The second component has a second connection portion on the side near the first component, and the second connection portion is electrically connected to the first connection portion.
7. The motor controller according to claim 5, characterized in that, The first cooling plate includes a first cooling section, and the first cooling section has a first liquid inlet; The first component includes a safety assembly, which is installed in the first cooling section and close to the first liquid inlet.
8. The motor controller according to claim 7, characterized in that, The first cooling plate further includes a second cooling section, which is in communication with the first cooling section; The second component also includes an inductor assembly, which is mounted on the second cooling section.
9. The motor controller according to claim 8, characterized in that, The first cooling plate further includes a third cooling section, which is in communication with the second cooling section; The second component also includes a filter assembly, which is mounted on the third cooling section.
10. The motor controller according to claim 5, characterized in that, It also includes a connector that extends along a first direction and has a DC interface facing the first cooling plate, the DC interface being for the DC component to be inserted.
11. The motor controller according to any one of claims 3-9, characterized in that, The AC component includes an IGBT component, which is mounted on the second mounting surface of the first cooling plate.
12. The motor controller according to claim 11, characterized in that, The AC component also includes a heat-conducting element, one end of which is disposed on the IGBT assembly, and the IGBT assembly is mounted on the first cooling plate through the heat-conducting element.
13. The motor controller according to claim 12, characterized in that, The first cooling plate has a receiving groove, and the end of the heat-conducting element away from the IGBT assembly is received in the receiving groove.
14. The motor controller according to claim 11, characterized in that, The AC component also includes a Hall effect sensor, which is mounted on the first cooling plate, located on one side of the IGBT component, and electrically connected to the IGBT component.
15. The motor controller according to claim 14, characterized in that, The AC component also includes a three-phase component, which is mounted on the first cooling plate, located on the side of the Hall component away from the IGBT component, and electrically connected to the IGBT component.
16. The motor controller according to claim 15, characterized in that, The IGBT assembly includes a third connection portion that passes through the Hall element and is connected to the three-phase assembly.
17. The motor controller according to claim 3, characterized in that, It also includes a second cooling plate disposed on one side of the first cooling plate along a third direction. The second cooling plate and the first cooling plate cooperate to cool the DC component and the AC component. Wherein, the third direction intersects with the first direction.
18. The motor controller according to claim 17, characterized in that, It also includes a capacitor assembly configured to be mounted on the side of the second cooling plate facing the first cooling plate.
19. The motor controller according to claim 18, characterized in that, It also includes two third cooling plates, which are disposed on opposite sides of the first cooling plate along the second direction and are both connected to the first cooling plate. One of the third cooling plates is also connected to the second cooling plate. Wherein, the second direction intersects with the first direction and also intersects with the third direction.
20. A drive assembly, characterized in that, Including the motor controller as described in any one of claims 1-19.
21. The drive assembly according to claim 20, characterized in that, It also includes a drive motor, which is located below the motor controller in a first direction, such that the drive motor is electrically connected to the AC component.
22. The drive assembly according to claim 21, characterized in that, A first cooling channel is formed in the first cooling plate, and a second cooling channel is formed in the drive motor. The first cooling channel and the second cooling channel are connected so that the cooling medium flows from the second cooling channel to the first cooling channel.
23. A vehicle, characterized in that, Includes the motor controller as described in any one of claims 1-19 and / or the drive assembly as described in any one of claims 20-22.