Integrated anti-interference filter for new energy automobile motor controller
Patent Information
- Application Number
- CN202610976577.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-07-02
- Publication Date
- 2026-09-25
AI Technical Summary
[0003]本发明的目的在于提供一种新能源汽车电机控制器用集成式抗干扰滤波器，通过将两根滤波导线分别设置在两个倾斜并垂直的倾斜壁上实现铜排之间没有正对面，并通过优化和改善线圈和电容布局，来达到逐级吸收和降低高频位移电流和寄生电容，解决了现有的导线之间正对面积导致寄生电容很难消除，高频位移电流的大小不同处理困难等问题
[0024]1、本发明将滤波导线中的铜排导线做成扁平状，两个导线上的铜排导线倾斜朝上呈45°，使得两个导线上的铜排导线的面之间夹角呈90°，没有有效的正对面积，再加上两个滤波导线中铜排导线之间是交错分布的，因此实现两根滤波导线之间的共模干扰极低，而两根滤波导线中线圈也是上下错位，不会产生相互磁感干扰，再加上中间设置的屏蔽隔板能有效两侧的线圈之间干扰，使得共模干扰极大降低。
Smart Images
Figure CN122824142A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of filter technology, and in particular relates to an integrated anti-interference filter for a new energy vehicle motor controller. Background Technology
[0002] In new energy electric vehicles, the motor controller generates electromagnetic interference (EMI) at various frequencies. This interference can affect the vehicle's electronic systems, communication equipment, and surrounding radio equipment. Filters are typically used to suppress EMI. Because it's easy for two wires to be directly aligned during layout, it's difficult to avoid spatial alignment, making it hard to prevent parasitic capacitance between the wires. When DC power is input into the motor controller, it undergoes nearly ten thousand changes per second via a high-frequency switching mechanism, resulting in high-frequency displacement current. It's difficult to effectively handle high-frequency displacement currents of varying magnitudes and frequency bands. Furthermore, coil arrangement can also cause mutual interference between coils. Summary of the Invention
[0003] The purpose of this invention is to provide an integrated anti-interference filter for a new energy vehicle motor controller. By setting two filter wires on two inclined and vertical inclined walls respectively, the copper busbars are not directly opposite each other. By optimizing and improving the layout of coils and capacitors, the high-frequency displacement current and parasitic capacitance are absorbed and reduced step by step. This solves the problems of existing wires facing each other, which make it difficult to eliminate parasitic capacitance and difficult to handle high-frequency displacement current of different magnitudes.
[0004] To solve the above-mentioned technical problems, the present invention is achieved through the following technical solution:
[0005] This invention relates to an integrated anti-interference filter for a new energy vehicle motor controller, comprising a mounting box, filter wires, an X capacitor unit, and a Y capacitor unit;
[0006] The installation box includes a box body, a box cover and end plates. The box body has an inverted protruding cavity. Grounding capacitor cavities are provided below the two sides of the inverted protruding cavity of the box body. The two inclined walls of the inverted protruding cavity are symmetrically arranged and the included angle between the two inclined walls is 90°. A shielding partition is inserted in the middle of the inverted protruding cavity.
[0007] The filter conductor includes a first conductor and a second conductor. Both the first conductor and the second conductor include multiple copper busbar conductors and multiple filter coils. Adjacent copper busbar conductors are connected by a filter coil. The included angle between adjacent copper busbar conductors is 90°. The first conductor and the second conductor are detached from the inclined wall by a bracket and installed on the inclined wall. The copper busbar conductors on the first conductor and the second conductor are parallel to the corresponding inclined wall. When the first conductor and the second conductor are projected onto the shielding partition, the projections of the copper busbar conductors on the first conductor and the second conductor are perpendicular to each other.
[0008] The first and second conductors are electrically connected to an X capacitor unit. The capacitor modules on the X capacitor unit are all mounted on a shielding partition. A Y capacitor unit is installed in each of the two grounding capacitor cavities. One end of each Y capacitor unit passes through the inclined wall and is connected to the first and second conductors. A grounding copper busbar is provided at the bottom corner of the grounding capacitor cavity. The other end of the Y capacitor unit is connected to the grounding copper busbar.
[0009] The present invention is further configured such that the surfaces of the copper busbar conductor and the filter coil are both coated with insulating varnish, the copper busbar conductor is 1-2 mm thick and 5-10 mm wide, and the filter coil is made of circular wire wound around.
[0010] The bracket has two high-temperature resistant insulating ceramic retaining rings at the top. The filter coil is clamped on the high-temperature resistant insulating ceramic retaining rings. There is a 15-25mm gap between the copper busbar wire and the inclined wall. The length of the copper busbar wire is 50-100mm.
[0011] The first and second conductors are provided with inlet copper busbar conductors and outlet copper busbar conductors at both ends.
[0012] The present invention is further configured such that the number of filter coils on the first wire and the second wire increases progressively from the end of the copper busbar to the end of the copper busbar, the number of filter coils on the first wire and the second wire is equal, and the size of the filter coils at corresponding positions on the first wire and the second wire is the same.
[0013] The present invention is further configured such that the X capacitor unit includes at least three X capacitors, and one X capacitor is connected at the midpoint between two opposing copper busbars at the relative positions of the first wire and the second wire;
[0014] The capacitance of the multiple X capacitors decreases progressively from the copper busbar wire outlet to the copper busbar wire inlet.
[0015] The present invention is further configured such that the Y capacitor unit includes a plurality of Y capacitors;
[0016] The first and second wires are each connected to a Y capacitor on the copper busbar wire at the pin connection position of each X capacitor. The Y capacitor is electrically connected to the copper busbar wire with its pins passing through the inclined wall.
[0017] The grounding capacitor cavity is equipped with a capacitor mounting plate, and the main body of the Y capacitor is mounted on the capacitor mounting plate.
[0018] The present invention is further configured such that the Y capacitance on the first wire and the second wire decreases stepwise from the end of the copper busbar to the end of the copper busbar.
[0019] The present invention is further configured such that each of the X capacitor unit and the Y capacitor unit contains four capacitors, wherein the capacitance value of the X capacitor is 5-50μF and the capacitance value of the Y capacitor is 10-100nF;
[0020] Both the X capacitor and the Y capacitor are gradually reduced from the copper busbar outgoing wire end to the copper busbar incoming wire end by a factor of 0.4-0.6.
[0021] The present invention is further configured such that the box body is sealed with a box cover on the top and sealing plates are installed at both ends of the box body, so that the inverted protrusion cavity inside the box body is in a sealed state and the air inside the inverted protrusion cavity is replaced with nitrogen.
[0022] The present invention is further configured such that the box body, box cover and end plate are all made of die-cast aluminum and coated with an insulating ceramic layer.
[0023] The present invention has the following beneficial effects:
[0024] 1. In this invention, the copper busbars in the filter conductors are made flat, and the copper busbars on the two conductors are tilted upwards at 45°, so that the angle between the surfaces of the copper busbars on the two conductors is 90°, with no effective direct facing area. In addition, the copper busbars in the two filter conductors are staggered, thus achieving extremely low common-mode interference between the two filter conductors. The coils in the two filter conductors are also staggered vertically, so they will not generate mutual magnetic interference. In addition, the shielding partition in the middle can effectively reduce interference between the coils on both sides, thus greatly reducing common-mode interference.
[0025] 2. In this invention, when the high-frequency switching switch changes nearly 10,000 times per second, resulting in high-frequency displacement current, the high-frequency displacement current is absorbed by coils set in stages to gradually reduce the impact of the high-frequency displacement current. This reduces the high-frequency displacement current at each copper busbar conductor position and reduces the parasitic capacitance and its magnitude. Furthermore, X capacitors and Y capacitors of different capacitance values are set at each copper busbar conductor position to guide the parasitic capacitance and prevent it from flowing to the battery, thus greatly improving the protection of the battery.
[0026] Of course, any product implementing this invention does not necessarily need to achieve all of the advantages described above at the same time. Attached Figure Description
[0027] To more clearly illustrate the technical solutions of the embodiments of the present invention, 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 the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0028] Figure 1This is a schematic diagram of the overall structure of an integrated anti-interference filter for a new energy vehicle motor controller.
[0029] Figure 2 This is a schematic diagram of the internal structure of an integrated anti-interference filter for a new energy vehicle motor controller.
[0030] Figure 3 This is a schematic diagram of the internal filter wire structure of an integrated anti-interference filter for a new energy vehicle motor controller.
[0031] Figure 4 This is a schematic diagram of the box body.
[0032] Figure 5 This is the structure of a filter wire.
[0033] Figure 6 This is a schematic diagram of the circuit principle of an integrated anti-interference filter for a new energy vehicle motor controller (viewed from top).
[0034] The attached diagram lists the components represented by each number as follows:
[0035] 1. Box body; 11. Box cover; 12. Blocking plate; 13. Inverted boss cavity; 131. Inclined wall; 132. Bracket; 133. High temperature resistant insulating ceramic retaining ring; 14. Grounding capacitor cavity; 2. Filter wire; 21. Copper busbar wire; 22. Filter coil; 3. X capacitor unit; 31. First X capacitor; 32. Second X capacitor; 33. Third X capacitor; 34. Fourth X capacitor; 4. Y capacitor unit; 41. First Y capacitor; 42. Second Y capacitor; 43. Third Y capacitor; 44. Fourth Y capacitor; 5. Shielding partition; 6. Capacitor mounting plate; 7. Grounding copper busbar; 01. Connecting copper busbar wire; 02. Disconnecting copper busbar wire. Detailed Implementation
[0036] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0037] Please see Figure 1-6 The present invention is an integrated anti-interference filter for a new energy vehicle motor controller, comprising a mounting box, filter wires 2, an X capacitor unit 3, and a Y capacitor unit 4;
[0038] The mounting box includes a box body 1, a box cover 11, and end plates 12 at both ends. The box body 1 has an inverted protrusion cavity 13 inside. Grounding capacitor cavities 14 are provided below the two sides of the inverted protrusion cavity 13 of the box body 1. The two sides of the inverted protrusion cavity 13 are symmetrically arranged with an included angle of 90° between the two inverted walls 131. A shielding partition 5 is inserted into the middle of the inverted protrusion cavity 13.
[0039] The inverted protrusion cavity 13 structure can form two inclined walls 131 at a 45° angle to the horizontal plane, and the two inclined walls 131 are perpendicular to each other. In this way, the filter wires 2 can be installed inclined upwards, and there is basically no direct opposition between the filter wires 2, which greatly reduces common-mode interference. The shielding partition 5 can also shield the electric arc and interference between the filter coils 22.
[0040] The filter wire 2 includes a first wire and a second wire. Both the first wire and the second wire include multiple copper busbar wires 21 and multiple filter coils 22. Each adjacent copper busbar wire 21 is connected by a filter coil 22. The included angle between adjacent copper busbar wires 21 is 90°. The first wire and the second wire are detached from the inclined wall 131 by the bracket 132 and installed on the inclined wall 131. The copper busbar wires 21 on the first wire and the second wire are parallel to the corresponding inclined wall 131. When the first wire and the second wire are projected on the shielding partition 5, the projections of the copper busbar wires 21 on the first wire and the second wire are perpendicular to each other.
[0041] like Figure 2 , Figure 3 and Figure 6 The corresponding copper busbars 21 on the first and second conductors are staggered, with only the intersection points having direct opposite positions. In addition, the copper busbars 21 are tilted upwards, so that the copper busbars 21 on the first and second conductors do not have direct opposite positions. Furthermore, the included angle between adjacent copper busbars 21 is 90°, so the copper busbars 21 in the relative positions of the first and second conductors (the projections of the copper busbars 21 on the first and second conductors are perpendicular to each other) are staggered. The staggered arrangement means that there are only intersection points with direct opposite positions.
[0042] The first conductor and the second conductor are electrically connected to the X capacitor unit 3. The capacitor modules on the X capacitor unit 3 are all mounted on the shielding partition 5. A Y capacitor unit 4 is installed in each of the two grounding capacitor cavities 14. One end of each Y capacitor unit 4 is passed through the inclined wall and connected to the first conductor and the second conductor. A grounding copper busbar 7 is provided at the bottom corner of the grounding capacitor cavity 14. The other end of the Y capacitor unit 4 is connected to the grounding copper busbar 7.
[0043] X-capacitor unit 3 is connected between the first and second conductors and guides the capacitance generated between them. Y-capacitor unit 4 is used for the grounding capacitance corresponding to the first and second conductors. The grounding copper busbar 7 can be connected to the capacitors in the same Y-capacitor unit 4, and then the grounding copper busbar 7 is connected to the vehicle's shell.
[0044] The copper busbar conductor 21 and the filter coil 22 are both coated with insulating varnish. The copper busbar conductor 21 is 1-2 mm thick and 5-10 mm wide. The filter coil 22 is made of round wire wound around.
[0045] The bracket 132 has two high-temperature resistant insulating ceramic retaining rings 133 at the top. The filter coil 22 is clamped on the high-temperature resistant insulating ceramic retaining rings 133. The copper busbar wire 21 has a gap of 15-25mm between it and the inclined wall 131. The length of the copper busbar wire 21 is 50-100mm.
[0046] The first and second conductors are provided with a copper busbar 01 at one end and a copper busbar 02 at the other end.
[0047] The bracket 132 is insulated (the inner core metal is welded to the inclined wall 131 and wrapped with an insulating layer on the outside). The filter coil 22 is clamped on the high-temperature resistant insulating ceramic retainer 133, which makes the copper busbar wire 21 suspended. Without insulating material wrapped around the copper busbar wire 21, the parasitic capacitance is greatly reduced when it is suspended.
[0048] Copper busbar conductors of size 21, with a thickness of 1-2mm and a width of 5-10mm, are sufficient for tram use. For larger specifications...
[0049] The number of filter coils 22 on the first and second conductors increases progressively from the end of the copper busbar conductor 02 to the end of the copper busbar conductor 01. The number of filter coils on the first and second conductors is equal, and the filter coils 22 at corresponding positions on the first and second conductors are the same size.
[0050] The number of filter coils 22 is equal on the first and second conductors, and the number of coil turns increases gradually. When the high-frequency current changes to form alternating current at the automotive motor controller, the generated high-frequency displacement current will shift towards the battery end on the first and second conductors. Since the first filter coil 22 is subjected to the greatest impact, the first filter coil 22 (the one closest to the controller end) is made smaller. The position of the first filter coil 22 reduces the intensity of the high-frequency displacement current, so the impact intensity of the filter coil 22 will not be too large, but only weakened. The number of turns of the filter coil 22 gradually increases, but the high-frequency displacement current becomes smaller, which is more conducive to buffering. The function of the filter coil 22 is to pass low frequencies and block high frequencies, prevent the current from changing abruptly, and suppress the transient fluctuations of the current.
[0051] The X capacitor unit 3 includes at least three X capacitors, with one X capacitor connected in the middle of two opposing copper busbars at the relative positions of the first and second conductors.
[0052] The capacitance of the multiple X capacitors decreases progressively from the copper busbar wire 02 end to the copper busbar wire 01 end.
[0053] The X capacitor unit 3 is configured with four capacitors: the first X capacitor, the second X capacitor, the third X capacitor, and the fourth X capacitor. Setting up large capacitors in areas with high-frequency displacement current intensity can better cope with the capacitance generated by common mode.
[0054] The Y capacitor unit 4 includes multiple Y capacitors;
[0055] Similarly, there are four Y capacitor units 3, namely the first Y capacitor, the second Y capacitor, the third Y capacitor and the fourth Y capacitor.
[0056] The first and second wires are each connected to a Y capacitor on the copper busbar wire 21 at the pin connection position at both ends of each X capacitor. The Y capacitor is electrically connected to the copper busbar wire 21 with its pins passing through the inclined wall.
[0057] The grounding capacitor cavity 14 is provided with a capacitor mounting plate 6, and the main body of the Y capacitor is mounted on the capacitor mounting plate 6.
[0058] Since the parasitic capacitance is relatively large in areas with high frequency displacement current intensity, the frequency displacement current intensity will decrease relatively after passing through each filter coil 22. Therefore, the frequency displacement current intensity of the copper busbar 02 after the filter coil 22 is reduced. In addition, the Y capacitor is pulled to the grounding terminal (tram shell), which will reduce or be pulled in the direction, greatly reducing the displacement of the parasitic capacitance towards the battery terminal.
[0059] The Y capacitance on both the first and second conductors decreases progressively from the copper busbar conductor 02 end to the copper busbar conductor 01 end.
[0060] Both the X capacitor unit and the Y capacitor unit are provided with 4 capacitors. The capacitance value of the X capacitor is 5-50μF and the capacitance value of the Y capacitor is 10-100nF.
[0061] Both the X capacitor and the Y capacitor decrease progressively from the copper busbar wire 02 end to the copper busbar wire 01 end, by a factor of 0.4-0.6.
[0062] For example, the capacitance of the first X capacitor is 50 μF, the capacitance of the second X capacitor is 30 μF, the capacitance of the third X capacitor is 15 μF, and the capacitance of the fourth X capacitor is 6 μF.
[0063] For example, the capacitance of the first Y capacitor is 100nF, the capacitance of the second Y capacitor is 60nF, the capacitance of the third Y capacitor is 30nF, and the capacitance of the fourth Y capacitor is 12nF.
[0064] The capacitor values described above, which vary progressively, are examples. However, the values are not limited to these and can be adjusted based on the actual controller configuration and battery power supply conditions.
[0065] The box body 1 has a top sealing cover 11 and sealing plates 12 installed at both ends of the box body 1 to keep the inverted protrusion cavity 13 inside the box body 1 sealed, and the air inside the inverted protrusion cavity 13 is replaced with nitrogen.
[0066] Sealing the box and replacing it with dry nitrogen can reduce electric arcs, decrease the risk of fire, and increase safety.
[0067] The box body 1, box cover 11 and blocking plate 12 are all made of die-cast aluminum, and the surface is coated with an insulating ceramic layer.
[0068] The die-cast aluminum surface is coated with an insulating ceramic layer, ensuring that the interior of the enclosure is a shielded space, unaffected by external electromagnetic interference, and similarly, any electromagnetic interference generated will not interfere with the outside. It also provides insulation.
[0069] In the description of this specification, references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.
[0070] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to the specific implementations described. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.
Claims
1. An integrated anti-interference filter for a new energy vehicle motor controller, characterized in that: Includes mounting box, filter wire (2), X capacitor unit (3) and Y capacitor unit (4); The mounting box includes a box body (1), a box cover (11) and end plates (12) at both ends. The box body (1) has an inverted protrusion cavity (13) inside. Grounding capacitor cavities (14) are provided below the two sides of the inverted protrusion cavity (13) of the box body (1). The two sides of the inverted protrusion cavity (13) are symmetrically arranged with an included angle of 90° between the two inclined walls (131). A shielding partition (5) is inserted in the middle of the inverted protrusion cavity (13). The filter wire (2) includes a first wire and a second wire. Both the first wire and the second wire include multiple copper busbar wires (21) and multiple filter coils (22). Each adjacent copper busbar wire (21) is connected by a filter coil (22). The included angle between adjacent copper busbar wires (21) is 90°. The first wire and the second wire are separated from the inclined wall (131) by the bracket (132) and installed on the inclined wall (131). The copper busbar wires (21) on the first wire and the second wire are parallel to the corresponding inclined wall (131). When the first wire and the second wire are projected onto the shielding partition (5), the projections of the copper busbar wires (21) on the first wire and the second wire are perpendicular to each other. The first conductor and the second conductor are electrically connected to the X capacitor unit (3). The capacitor modules on the X capacitor unit (3) are all mounted on the shielding partition (5). A Y capacitor unit (4) is installed in each of the two grounding capacitor cavities (14). One end of each Y capacitor unit (4) is passed through the inclined wall and connected to the first conductor and the second conductor. A grounding copper busbar (7) is provided at the bottom corner of the grounding capacitor cavity (14). The other end of the Y capacitor unit (4) is connected to the grounding copper busbar (7).
2. The integrated anti-interference filter for a new energy vehicle motor controller according to claim 1, characterized in that, The copper busbar conductor (21) and the filter coil (22) are both coated with insulating varnish. The copper busbar conductor (21) is 1-2 mm thick and 5-10 mm wide. The filter coil (22) is made of round wire. The bracket (132) has two high-temperature resistant insulating ceramic retaining rings (133) at the top. The filter coil (22) is clamped on the high-temperature resistant insulating ceramic retaining rings (133). There is a gap of 15-25mm between the copper busbar wire (21) and the inclined wall (131). The length of the copper busbar wire (21) is 50-100mm. The first and second conductors are provided with a copper busbar (01) and a copper busbar (02) at both ends.
3. The integrated anti-interference filter for a new energy vehicle motor controller according to claim 2, characterized in that, The number of filter coils (22) on the first and second conductors increases progressively from the end of the copper busbar conductor (02) to the end of the copper busbar conductor (01). The number of filter coils on the first and second conductors is equal, and the filter coils (22) at corresponding positions on the first and second conductors are the same size.
4. The integrated anti-interference filter for a new energy vehicle motor controller according to claim 1, characterized in that, The X capacitor unit (3) includes at least three X capacitors, with one X capacitor connected in the middle of two opposing copper busbars at the relative positions of the first and second conductors; The capacitance of the multiple X capacitors decreases progressively from the end of the copper busbar wire (02) to the end of the copper busbar wire (01).
5. An integrated anti-interference filter for a new energy vehicle motor controller according to claim 4, characterized in that, The Y capacitor unit (4) includes multiple Y capacitors; The first and second wires are connected to a Y capacitor on the copper busbar wire (21) at the pin connection position at both ends of each X capacitor. The Y capacitor is electrically connected to the copper busbar wire (21) with its pins passing through the inclined wall. The grounding capacitor cavity (14) is provided with a capacitor mounting plate (6), and the main body of the Y capacitor is mounted on the capacitor mounting plate (6).
6. An integrated anti-interference filter for a new energy vehicle motor controller according to claim 5, characterized in that, The Y capacitance on the first and second conductors decreases step by step from the end of the copper busbar conductor (02) to the end of the copper busbar conductor (01).
7. An integrated anti-interference filter for a new energy vehicle motor controller according to claim 1, characterized in that, Both the X capacitor unit and the Y capacitor unit are provided with 4 capacitors. The capacitance value of the X capacitor is 5-50μF and the capacitance value of the Y capacitor is 10-100nF. The X capacitor and Y capacitor are both gradually reduced from the copper busbar wire (02) end to the copper busbar wire (01) end by a factor of 0.4-0.
6.
8. An integrated anti-interference filter for a new energy vehicle motor controller according to claim 1, characterized in that, The box body (1) has a box cover (11) on the top and a sealing plate (12) installed at both ends of the box body (1) to make the inverted protrusion cavity (13) inside the box body (1) sealed, and the air inside the inverted protrusion cavity (13) is replaced with nitrogen.
9. An integrated anti-interference filter for a new energy vehicle motor controller according to claim 1, characterized in that, The box body (1), box cover (11) and blocking plate (12) are all made of die-cast aluminum and coated with an insulating ceramic layer.