Motor controller, electric drive assembly and electric vehicle

Abstract

The application provides a motor controller, an electric drive assembly and an electric vehicle, and belongs to the technical field of electric vehicles.The power module and the plurality of capacitors of the motor controller provided by the application are arranged in a first direction, and the circuit board is stacked in a second direction on the power module and the plurality of capacitors.The power module comprises a direct-current copper bar, and each capacitor comprises a pin, which is directed towards the circuit board in the second direction and is used for electrically connecting the circuit board.The direct-current copper bar is used for transmitting direct current output by the power module to the circuit board or transmitting direct current transmitted by the circuit board to the power module.The pin is used for receiving the direct current transmitted by the circuit board and transmitting the direct current to the plurality of capacitors or transmitting the adjusted direct current of the plurality of capacitors to the circuit board, so that the circuit board is used for transmitting the current between the capacitors and the power module, the copper bar is saved, the volume is reduced, the current transmission impedance and the common mode inductance are reduced by transmitting the current through the circuit board, and the performance of the motor controller is improved.

Description

Technical Field

[0001] This application relates to the field of electric vehicle technology, and in particular to a motor controller, an electric drive assembly, and an electric vehicle. Background Technology

[0002] In electric vehicles, the motor controller is used to convert direct current (DC) to alternating current (AC). The motor controller can convert the DC power output from the battery into AC power to drive the motor and power the electric vehicle. Alternatively, the motor controller can act as a generator controller, converting the AC power generated by the generator into DC power to charge the battery. The capacitors and power modules in the motor controller are electrically connected via copper busbars and cables, resulting in a large system size, high stray inductance, and high impedance. Summary of the Invention

[0003] This application provides a motor controller, an electric drive assembly, and an electric vehicle, which reduces the size of the motor controller, lowers the current transmission impedance, and reduces unwanted inductance.

[0004] In a first aspect, this application provides a motor controller, which includes a circuit board, a power module, and multiple capacitors. The power module is used to convert between AC and DC power. The multiple capacitors are used to adjust the DC power and transmit it to a power battery to charge the power battery, or to adjust the DC power output from the power battery and transmit it to the power module. The circuit board is used to transmit signals to drive the power module. The power module and multiple capacitors are arranged in a planar configuration along a first direction, and the circuit board is stacked on top of the power module and multiple capacitors along a second direction, with the first direction perpendicular to the second direction. The power module includes a DC busbar, and each capacitor includes pins. The pins and the DC busbar both face the circuit board and are used for electrical connection to the circuit board. The DC busbar is used to transmit the DC power output from the power module to the circuit board, or to transmit the DC power transmitted from the circuit board to the power module. The pins are used to receive the DC power transmitted from the circuit board and transmit the DC power to the multiple capacitors, or to transmit the adjusted DC power from the multiple capacitors to the circuit board.

[0005] In this embodiment, the solution addresses the technical problems of large size, high stray inductance, and high impedance in motor controllers. By arranging the power module and multiple capacitors in a flat, stacked manner beneath the circuit board, and by ensuring the DC busbars of the power module and the leads of the capacitors face the circuit board, the DC busbars and leads stacked beneath the circuit board can be electrically connected to the circuit board. This allows the power module and capacitors to transmit current through the circuit board, eliminating the need for a connecting copper busbar between the power module and capacitors, reducing size, simplifying the structure, lowering production costs, and increasing power density. Compared to the method of transmitting current through a copper busbar, transmitting current between the power module and capacitors through the circuit board results in lower impedance and stray inductance, effectively reducing capacitor connection impedance and improving filtering performance. This achieves the technical benefits of a small motor controller size, low stray inductance, and low impedance, which is beneficial for optimizing the NVH performance of the motor controller, achieving better high-frequency ripple suppression, and increasing the power density of the motor controller.

[0006] In one embodiment, a DC busbar is used to transmit DC power along a second direction between the power module and the circuit board. The DC power transmitted to the circuit board flows within the circuit board in a plane perpendicular to the second direction. Pins are used to transmit DC power along the second direction between the circuit board and multiple capacitors.

[0007] In this embodiment, the solution shortens the current transmission path between the power module, multiple capacitors, and the circuit board, thereby achieving the technical effects of reducing impedance and decreasing the size of the motor controller. Since the circuit board is stacked above the power module and multiple capacitors, with the pins and DC busbars facing the circuit board along the second direction, the distance between the circuit board and the power module and multiple capacitors in the second direction is small. By using the DC busbar to transmit DC current along the second direction between the power module and the circuit board, the current transmission path between the DC busbar and the circuit board is shortened. Furthermore, by allowing the current transmitted to the circuit board to flow within the circuit board in a plane perpendicular to the second direction, the impedance is lower and the inductance is less compared to the busbar transmission. Finally, by using the DC busbar to transmit DC current along the second direction between the circuit board and multiple capacitors, the current transmission path between the multiple capacitors and the circuit board is shortened, thus achieving the technical effects of reducing impedance and decreasing the size of the motor controller.

[0008] In one embodiment, when the motor controller is used to generate electricity to charge the power battery, when the motor controller acts as a generator controller, the power module is used to convert AC power into DC power, the DC bus is used to transmit the DC power from the power module to the circuit board along the second direction, the DC power transmitted to the circuit board flows in the circuit board along a plane perpendicular to the second direction, and the pins are used to transmit the DC power output by the circuit board to multiple capacitors along the second direction, the multiple capacitors adjust the received DC power and transmit it to the power battery to charge the power battery.

[0009] In the embodiments of this application, this solution is used to shorten the current transmission path between the power module, multiple capacitors, and circuit board during power generation, thereby achieving the technical effects of reducing impedance and decreasing the size of the motor controller during power generation.

[0010] In one embodiment, when the motor controller is used to control the drive motor, multiple capacitors are used to adjust the DC power output from the power battery and transmit it to the circuit board through pins along the second direction. The DC power transmitted to the circuit board flows in a plane perpendicular to the second direction within the circuit board. A DC copper busbar is used to transmit the DC power output from the circuit board to the power module along the second direction. The power module is used to convert the DC power into AC power and transmit it to the drive motor to drive it.

[0011] In the embodiments of this application, this solution is used to shorten the current transmission path between the power module, multiple capacitors, and circuit board during the driving state, thereby achieving the technical effects of reducing impedance and reducing the size of the motor controller during the driving state.

[0012] In one embodiment, the motor controller further includes a DC connection copper busbar for transmitting DC power between multiple capacitors and a power battery. The DC connection copper busbar is distributed along a first direction on the side of the multiple capacitors facing away from the power module. A circuit board is stacked along a second direction on top of the power module, the multiple capacitors, and the DC connection copper busbar, with the DC connection copper busbar facing the circuit board and used for electrical connection to the circuit board.

[0013] In this embodiment, the solution shortens the internal current transmission path of the motor controller, reduces impedance, and reduces heat generation. By transmitting DC current between the capacitor and the DC connection copper busbar through the circuit board, the copper busbar between multiple capacitors and the DC connection copper busbar is eliminated, reducing volume and impedance. Furthermore, the arrangement of the DC connection copper busbar, multiple capacitors, and power modules in this solution results in a shorter power flow path between the DC connection channel and the power module, further reducing impedance and heat generation.

[0014] In one embodiment, the power module includes two DC busbars, each DC busbar including a connecting section and a bent section. One end of the connecting section extends out of the power module along a first direction, and the bent sections are distributed at one end of the connecting section along the first direction. The connecting sections of the two DC busbars are stacked at intervals along a second direction. The bent sections are bent toward the circuit board relative to the connecting sections. The bent sections are used to insert into and electrically connect to the circuit board. The bent sections of the two DC busbars are spaced apart along the first direction.

[0015] In this embodiment, the solution is used to reduce stray inductance of the DC copper busbar and avoid electrical interference, thereby effectively reducing stray inductance of the power circuit in the motor controller and improving the stability of the motor controller. Since the two DC copper busbars need to be electrically connected to the circuit board, bending the bent sections toward the circuit board makes the connection to the circuit board more convenient. By stacking the connecting sections at intervals in the second direction and spacing the bent sections in the first direction, both the stray inductance of the DC copper busbar and electrical interference are taken into account.

[0016] In one embodiment, the bent sections of the two DC copper busbars are staggered along a third direction, which is perpendicular to the first and second directions, and the distance between the bent sections of the two DC copper busbars along the third direction is greater than the distance between the bent sections of the two DC copper busbars along the first direction.

[0017] In this embodiment, the solution simultaneously reduces the size of the motor controller and improves electrical isolation. By offsetting the two bending segments along a third direction, the electrical isolation between the two bending segments is improved. Since offsetting the two bending segments in the third direction satisfies the condition for electrical isolation, and by making the distance between the two bending segments in the third direction greater than the distance in the first direction, the size occupied by the two DC copper busbars in the first direction is smaller. This allows for more space inside the motor controller to accommodate other components, or allows for a more compact arrangement of the power module and other components, which is beneficial for reducing the size of the motor controller.

[0018] In one embodiment, two DC copper busbars and a plurality of capacitors are arranged at intervals along a first direction, with the bent sections of the two DC copper busbars distributed between the connecting section and the plurality of capacitors along the first direction.

[0019] In this embodiment, the solution distributes the bending segment between the connecting segment and the multiple capacitors, making the bending segment and the multiple capacitors closer together. This helps to shorten the distance between the first conductive layer and the second conductive layer connecting the bending segment and the multiple capacitors in the circuit board, thereby improving the current transmission effect and reducing impedance.

[0020] In one embodiment, the plurality of capacitors includes a bus capacitor, which includes a plurality of pins. The bus capacitor includes two first sides along a first direction and two second sides arranged opposite each other along a third direction, which is perpendicular to the first and second directions. Two DC copper busbars of the power module are adjacent to one of the first sides along the first direction. Wherein, the distance between each pin of the bus capacitor and a first side along the first direction is greater than the distance between any pin of the bus capacitor and its adjacent second side along the third direction.

[0021] In this embodiment, since the bus capacitor is adjacent to the DC busbar of the power module, the pins of the bus capacitor are distributed away from a first side near the bend section to avoid interference between the pins of the bus capacitor and the DC busbar when the bus capacitor is inserted into the circuit board, thereby improving the electrical isolation effect.

[0022] In one embodiment, the plurality of capacitors include a capacitor having two pins, one pin of which is used for electrical connection via a circuit board to a DC copper busbar of a power module, and the other pin of which is used for electrical connection to a ground plane within the circuit board.

[0023] In this embodiment, the capacitor is used to filter out common-mode interference, improve the filtering effect of the switching frequency band, and enhance the EMC performance of the motor controller. The capacitor connects to a DC copper busbar and ground plane of the power module via two pins on the circuit board, reducing impedance compared to connecting the capacitor directly to the power module via a copper busbar.

[0024] In one embodiment, the circuit board includes a mounting hole, and the motor controller includes a fixing member for passing through the mounting hole to fix the circuit board and the housing of the motor controller. The fixing member is used to electrically connect the ground layer of the circuit board and the housing of the motor controller. In this embodiment, capacitor grounding is achieved by electrically connecting the grounding layer in the circuit board to the fixing member in the fixing hole of the circuit board, reusing the fixing hole and simplifying the grounding structure.

[0025] In one embodiment, the circuit board includes a first conductive layer, a ground layer, and a second conductive layer, which are arranged sequentially at intervals along a second direction. The first and second conductive layers are used to transmit direct current, and the ground layer is used to electrically connect to the housing of the motor controller. The first conductive layer and the ground layer are used to filter out common-mode interference generated by the power module, and the second conductive layer and the ground layer are also used to filter out common-mode interference generated by the power module.

[0026] In this embodiment, the solution reuses two conductive layers (first and second) for transmitting DC power and a ground layer to form an equivalent capacitor and reduce impedance. This improves the filtering effect on the current in the motor controller and also increases the insertion loss of the equivalent capacitor, reducing its equivalent impedance at high frequencies. This results in insertion loss significantly better than traditional solutions in critical high-risk frequency bands, effectively suppressing electromagnetic interference. Furthermore, it reduces the number of capacitors inserted into the circuit board, decreases the size of the motor controller, simplifies the installation process, and improves production efficiency.

[0027] In one embodiment, a first conductive layer and a ground layer are used to filter out high-frequency common-mode interference generated by the power module, a second conductive layer and a ground layer are used to filter out high-frequency common-mode interference generated by the power module, and two capacitors of the motor controller are used to filter out low-frequency common-mode interference generated by the power module. The high-frequency interference is greater than the low-frequency interference.

[0028] In this embodiment, the first conductive layer, the second conductive layer and the ground layer form an equivalent capacitor, and the two capacitors work together to filter out high-frequency common-mode interference and low-frequency common-mode interference generated by the power module. The two are combined to form a wideband composite filter network, which improves the filtering effect, enhances the stability of the motor controller and optimizes NVH performance.

[0029] In one embodiment, the power module is used to convert alternating current to direct current, and multiple capacitors are used to adjust the direct current and transmit it to the power battery to charge the power battery. The power module includes a fast recovery diode and an insulated gate bipolar transistor, and the area of ​​the fast recovery diode is larger than the area of ​​the insulated gate bipolar transistor.

[0030] In this embodiment, the motor controller is used for power generation, serving as a generator controller. This solution balances meeting power generation requirements with cost reduction. During power generation, the power required by the insulated-gate bipolar transistor (IGBT) in the motor controller is relatively low; by reducing the area of ​​the IGBT, power generation requirements can be met while simultaneously reducing costs.

[0031] In one embodiment, the power module includes a plurality of signal pins for transmitting signals and for inserting into and electrically connecting to a circuit board, wherein the orientation of the DC busbar along the second direction is the same as the orientation of the plurality of signal pins of the power module.

[0032] In this embodiment, by aligning the DC busbar with the signal pins of the power module, the DC busbar is inserted simultaneously with the signal pins of the power module when the circuit board is inserted along the second direction, simplifying the installation.

[0033] In one embodiment, the housing of the motor controller includes a bottom shell and a cover plate. The cover plate is stacked on the bottom shell along a second direction and encloses an opening in the bottom shell. The bottom shell is used to fix a circuit board, a power module, and multiple capacitors. The circuit board is stacked on the side of the power module and multiple capacitors opposite to the bottom shell along the second direction, and the cover plate is stacked on the side of the circuit board opposite to the power module and multiple capacitors along the second direction.

[0034] In this embodiment, since the power module and multiple capacitors are fixed to the circuit board, and the circuit board is stacked on the power module and multiple capacitors along the second direction, the mounting direction of the circuit board and the cover plate is consistent, the assembly direction is unified, and the process is simplified.

[0035] In one embodiment, the motor controller includes at least one heat sink located below the power module, above the circuit board, or below a plurality of capacitors, such that the heat sink can be used for at least one of the power module, the circuit board, and the plurality of capacitors.

[0036] In this embodiment, since the power module and multiple capacitors are electrically connected through the circuit board, the circuit board generates a lot of heat. By cooling the power module, circuit board, and multiple capacitors with a heat sink, the size of the motor controller is reduced, the current transmission impedance is reduced, and the inductance is reduced, while the operating temperature of the motor controller is lowered, thereby improving the operating efficiency of the motor controller.

[0037] Secondly, embodiments of this application provide an electric drive assembly, which includes a generator and a motor controller as described in any of the first aspects, wherein the power module of the motor controller is used to electrically connect to the generator to receive AC power. Alternatively, the electric drive assembly includes a drive motor and a motor controller as described in any of the first aspects, wherein the power module of the motor controller is used to convert DC power transmitted from the power battery into AC power and then transmit it to the drive motor.

[0038] In this embodiment, the motor controller in the electric drive assembly achieves a reduction in size, current transmission impedance, and noise inductance through the structural design of the power module, multiple capacitors, and circuit board. This optimizes the NVH performance and increases the power density of the motor controller, which in turn facilitates the miniaturization of the electric drive assembly, optimizes its NVH performance, and increases its power density.

[0039] Thirdly, embodiments of this application provide an electric vehicle, which includes a power battery and an electric drive assembly as described in the second aspect, the electric drive assembly being used to charge the power battery or to drive the wheels of the electric vehicle.

[0040] In the embodiments of this application, the structural design of the power module, multiple capacitors and circuit boards in the motor controller is conducive to miniaturization of the electric drive assembly, optimization of the NVH performance of the electric drive assembly and improvement of the power density of the electric drive assembly, thereby improving the performance of electric vehicles. Attached Figure Description

[0041] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the embodiments of this application will be described below.

[0042] Figure 1 This is a schematic diagram of an electric vehicle provided in an embodiment of this application; Figure 2 This is a schematic diagram of an electric drive assembly provided in an embodiment of this application; Figure 3 This is another schematic diagram of the electric drive assembly provided in the embodiments of this application; Figure 4 This is a schematic diagram of a motor controller provided in an embodiment of this application; Figure 5 This is a schematic diagram of a motor controller with the circuit board removed according to an embodiment of this application; Figure 6 This is a schematic diagram of the internal component distribution of the motor controller provided in an embodiment of this application; Figure 7 This is another schematic diagram of the internal component distribution of the motor controller provided in the embodiments of this application; Figure 8 This is a schematic diagram of a circuit board, DC copper busbar, and pins provided in an embodiment of this application; Figure 9 yes Figure 6 Enlarged view of section M; Figure 10 yes Figure 7 Enlarged view of section N; Figure 11 This is a schematic diagram of a power module provided in an embodiment of this application; Figure 12 This is another schematic diagram of the internal components of the motor controller provided in the embodiments of this application; Figure 13 This is another schematic diagram of the power module provided in the embodiments of this application. Detailed Implementation

[0043] The technical solutions of the embodiments of this application will be described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments.

[0044] To reduce the size of the motor controller, lower current transmission impedance, and reduce unwanted inductance, the power module and multiple capacitors of the motor controller provided in this application are arranged in a flat configuration along a first direction, and a circuit board is stacked on top of the power module and multiple capacitors along a second direction, with the first direction perpendicular to the second direction. The power module includes a DC busbar, and each capacitor includes pins. Along the second direction, both the pins and the DC busbar face the circuit board and are used for electrical connection to the circuit board. The DC busbar is used to transmit DC power output from the power module to the circuit board or to transmit DC power transmitted from the circuit board to the power module. The pins are used to receive DC power transmitted from the circuit board and transmit the DC power to the multiple capacitors or to transmit the adjusted DC power from the multiple capacitors to the circuit board. This allows the circuit board to transmit the current between the capacitors and the power module, saving copper busbars, reducing size, and reducing current transmission impedance and unwanted inductance by transmitting current through the circuit board, thereby improving the performance of the motor controller.

[0045] Figure 1 This is a schematic diagram of an electric vehicle 1 provided in an embodiment of this application.

[0046] In one embodiment, such as Figure 1 As shown, the electric vehicle 1 includes an electric drive assembly 11, which is used to drive the wheels 12 of the electric vehicle 1 or to generate electricity to charge the power battery 13.

[0047] Figure 2 This is a schematic diagram of an electric drive assembly 11 provided in an embodiment of this application.

[0048] In one embodiment, combined with Figure 1 and Figure 2 The electric drive assembly 11 includes a generator 20 and a motor controller 10. The electric drive assembly 11 is used to generate electricity to charge the power battery 13. The motor controller 10 can also be referred to as a generator controller.

[0049] In this embodiment, the generator 20 is used to receive the drive of the engine 30 to generate alternating current, which is transmitted to the motor controller 10. The motor controller 10 is used to convert the alternating current into direct current and transmit the direct current to the power battery 13 to charge the power battery 13.

[0050] In one embodiment, the electric drive assembly 11 includes a gearbox 40. The crankshaft of the engine 30 is used to drive the gearbox 40 and transmit power to the rotor of the generator 20 through gears in the gearbox 40 to drive the stator of the generator 20 to generate alternating current. The alternating current generated by the stator of the generator 20 is converted into direct current by the motor controller 10 and transmitted to the power battery 13 to charge the power battery 13.

[0051] Figure 3 This is another schematic diagram of the electric drive assembly 11 provided in the embodiments of this application.

[0052] In one embodiment, combined with Figure 1 and Figure 3 The electric drive assembly 11 includes a drive motor 50 and a motor controller 10. The electric drive assembly 11 is used to drive the wheels 12 of the electric vehicle 1.

[0053] In this embodiment, the DC power output from the power battery 13 is converted into AC power by the motor controller 10 and transmitted to the drive motor 50 to drive the rotor of the drive motor 50 to rotate. The drive motor 50 transmits power to the reducer 60 for speed change and then to the differential, which drives the wheels 12 of the electric vehicle 1.

[0054] In one embodiment, such as Figure 1 As shown, the electric vehicle 1 includes two electric drive assemblies, one denoted as electric drive assembly 11 and the other as electric drive assembly 11a. Electric drive assembly 11 generates electricity to charge the power battery 13, while electric drive assembly 11a drives the rear wheels 12 of the electric vehicle 1, and electric drive assembly 11 drives the front wheels 12 of the electric vehicle 1. Electric drive assembly 11a and electric drive assembly 11 can drive the wheels 12 individually or jointly drive the front and rear wheels 12. In one embodiment, electric drive assembly 11 can serve as an auxiliary drive assembly for the electric vehicle 1, and electric drive assembly 11a can serve as the rear active drive assembly for the electric vehicle 1.

[0055] As an important component of the electric drive assembly 11, the motor controller 10 is designed to be compatible with the small electric vehicle 1, optimize the NVH of the motor controller 10, and increase the power density of the motor controller 10. In order to make the motor controller 10 adaptable to the small space of the electric vehicle 1 and to optimize the NVH of the motor controller 10 and increase the power density of the motor controller 10, the motor controller 10 provided in this application achieves a reduction in the size of the motor controller 10, a reduction in current transmission impedance, and a reduction in parasitic inductance through the structural design between the power module 100, multiple capacitors 300 and the circuit board 200, thereby optimizing the NVH of the motor controller 10 and increasing the power density of the motor controller 10.

[0056] The motor controller 10 of this application is described in detail below.

[0057] Figure 4 This is a schematic diagram of a motor controller 10 provided in an embodiment of this application. Figure 5 This is a schematic diagram of a motor controller 10 with the circuit board 200 removed, provided in an embodiment of this application. Figure 6 This is a schematic diagram of the internal component distribution of the motor controller 10 provided in an embodiment of this application. Figure 7 This is another schematic diagram of the internal component distribution of the motor controller 10 provided in the embodiments of this application.

[0058] In one embodiment, combined with Figures 4 to 7The motor controller 10 includes a power module 100, which is used to convert between AC and DC power.

[0059] In the embodiments of this application, see Figure 7 The power module 100 includes one or more power modules 102, each power module 102 including a power switching transistor (not shown) for converting between AC and DC power. The power module 100 includes multiple signal pins 101 for connecting to the circuit board 200 to receive or transmit signals. In one embodiment, the signal pins 101 are used to transmit drive signals or temperature signals, etc.

[0060] In one embodiment, combined with Figures 4 to 7 The motor controller 10 includes a circuit board 200, which is used to transmit signals to drive the power module 100.

[0061] In this embodiment, the circuit board 200 is used to transmit signals to drive the power module 100. The circuit board 200 is also used to connect to an external controller to receive signals from the external controller to drive the power module 100. The circuit board 200 has a signal transmission layer (not shown). In one embodiment, the signal transmission layer is distributed on the surface or inside the circuit board 200, and the signal transmission layer is a conductive layer, such as a metal layer.

[0062] In one embodiment, see [reference] Figure 4 The circuit board 200 is connected to an external controller via a signal connector 205 to transmit limit signals.

[0063] In one embodiment, combined with Figures 4 to 7 The motor controller 10 includes multiple capacitors 300, which are used to adjust the DC power and transmit it to the power battery 13 to charge the power battery 13, or to adjust the DC power output from the power battery 13 and transmit it to the power module 100.

[0064] In the embodiments of this application, the multiple capacitors 300 adjust the DC current, including at least one function such as buffering, decoupling, voltage stabilization, and filtering.

[0065] In one embodiment, combined with Figures 4 to 5 The motor controller 10 includes a housing 400 for accommodating a circuit board 200, a power module 100, and multiple capacitors 300.

[0066] In one embodiment, combined with Figures 4 to 7The motor controller 10 includes a circuit board 200, a power module 100, and multiple capacitors 300. The multiple capacitors 300 are used to adjust the DC power and transmit it to the power battery 13 to charge the power battery 13, or to adjust the DC power output from the power battery 13 and transmit it to the power module 100. The circuit board 200 is used to transmit signals to drive the power module 100.

[0067] In this embodiment, when the motor controller 10 acts as a generator controller, the power module 100 converts the AC power output by the generator 20 into DC power. Multiple capacitors 300 then perform voltage regulation, filtering, and other adjustments on the DC power before transmitting it to the power battery 13 to charge the power battery 13.

[0068] In this embodiment, when the motor controller 10 controls the drive motor 50, multiple capacitors 300 adjust the DC power output from the power battery 13 by voltage regulation and filtering before transmitting it to the power module 100. The power module 100 converts the DC power adjusted by the multiple capacitors 300 into AC power and transmits it to the drive motor 50 to drive the wheels 12 of the electric vehicle 1.

[0069] In one embodiment, combined with Figures 4 to 7 A power module 100 and multiple capacitors 300 are arranged in a planar configuration along a first direction X. A circuit board 200 is stacked on top of the power module 100 and the multiple capacitors 300 along a second direction Z, where the first direction X is perpendicular to the second direction Z. The power module 100 includes a DC bus 103 facing the circuit board 200 and used for electrical connection to the circuit board 200. Each capacitor 300 includes a pin 301 facing the circuit board 200 and used for electrical connection to the circuit board 200. The DC bus 103 is used to transmit DC power output from the power module 100 to the circuit board 200 or to transmit DC power transmitted from the circuit board 200 to the power module 100. The pin 301 is used to receive DC power transmitted from the circuit board 200 and transmit the DC power to the multiple capacitors 300 or to transmit the adjusted DC power from the multiple capacitors 300 to the circuit board 200.

[0070] In this embodiment, the solution addresses the technical problems of large size, high stray inductance, and high impedance of the motor controller 10. By arranging the power module 100 and multiple capacitors 300 in a flat configuration, both are stacked beneath the circuit board 200. With the DC busbar 103 of the power module 100 and the pins 301 of the capacitors 300 facing the circuit board 200, the DC busbar 103 and pins 301 stacked beneath the circuit board 200 can be electrically connected to the circuit board 200. This allows the power module 100 and capacitors 300 to transmit current through the circuit board 200, eliminating the need for a connecting copper busbar between the power module 100 and capacitors 300, reducing size, simplifying the structure, lowering production costs, and increasing power density. Compared to the method of transmitting current via a copper busbar, transmitting current between the power module 100 and capacitors 300 through the circuit board 200 results in lower impedance and stray inductance, effectively reducing the impedance of capacitors 300 and improving filtering performance. This achieves the technical effects of small size, low stray inductance and low impedance of motor controller 10, which is conducive to optimizing the NVH of motor controller 10, achieving better high-frequency ripple suppression effect and improving the power density of motor controller 10.

[0071] In this embodiment, by having both pin 301 and DC bus 103 facing the circuit board 200 along the second direction Z, the circuit board 200 can directly connect pin 301 and DC bus 103, making it easier to install the power module 100 and capacitor 300 onto the circuit board 200 and resulting in a smaller size in the second direction Z after assembly.

[0072] In one embodiment, see [reference] Figure 6 The DC bus 103 is used to transmit DC power along the second direction Z between the power module 100 and the circuit board 200. The DC power transmitted to the circuit board 200 flows in the circuit board 200 along a plane perpendicular to the second direction Z. The pin 301 is used to transmit DC power along the second direction Z between the circuit board 200 and multiple capacitors 300.

[0073] In this embodiment, the solution is used to shorten the current transmission path between the power module 100, multiple capacitors 300, and circuit board 200, thereby achieving the technical effects of reducing impedance and reducing the size of the motor controller 10. Since the circuit board 200 is stacked above the power module 100 and multiple capacitors 300, and the pins 301 and the DC bus 103 along the second direction Z are both facing the circuit board 200, the spacing between the circuit board 200 and the power module 100 and multiple capacitors 300 in the second direction Z is small. By using the DC bus 103 to transmit DC power along the second direction Z between the power module 100 and the circuit board 200, the current transmission path between the DC bus 103 and the circuit board 200 is shortened. By having the current transmitted to the circuit board 200 flow in a plane perpendicular to the second direction Z inside the circuit board 200, the transmission impedance is smaller and the inductance is less than that of the copper bus. By using the DC bus 103 to transmit DC power along the second direction Z between the circuit board 200 and multiple capacitors 300, the current transmission path between the multiple capacitors 300 and the circuit board 200 is shortened. This achieves the technical effect of shortening the current transmission path between the power module 100, multiple capacitors 300, and the circuit board 200, thereby reducing impedance and reducing the size of the motor controller 10.

[0074] In one embodiment, combined with Figure 2 and Figure 6 When the motor controller 10 is used to generate electricity to charge the power battery 13, when the motor controller 10 acts as a generator controller, the power module 100 is used to convert AC power into DC power, the DC bus 103 is used to transmit DC power from the power module 100 to the circuit board 200 along the second direction Z, the DC power transmitted to the circuit board 200 flows in the circuit board 200 along a plane perpendicular to the second direction Z, the pin 301 is used to transmit the DC power output from the circuit board 200 along the second direction Z to multiple capacitors 300, the multiple capacitors 300 adjust the received DC power and transmit it to the power battery 13 to charge the power battery 13.

[0075] In this embodiment of the application, the solution is used to shorten the current transmission path between the power module 100, multiple capacitors 300, and circuit board 200 during power generation, thereby achieving the technical effect of reducing impedance and reducing the size of the motor controller 10 during power generation.

[0076] In one embodiment, combined with Figure 3 and Figure 6When the motor controller 10 is used to control the drive motor 50, multiple capacitors 300 are used to adjust the DC power output from the power battery 13 and transmit it to the circuit board 200 along the second direction Z through pin 301. The DC power transmitted to the circuit board 200 flows in the circuit board 200 along a plane perpendicular to the second direction Z. The DC copper busbar 103 is used to transmit the DC power output from the circuit board 200 to the power module 100 along the second direction Z. The power module 100 is used to convert the DC power into AC power and transmit it to the drive motor 50 to drive it.

[0077] In this embodiment of the application, the solution is used to shorten the current transmission path between the power module 100, multiple capacitors 300, and circuit board 200 in the driving state, thereby achieving the technical effect of reducing impedance and reducing the size of the motor controller 10 in the driving state.

[0078] Figure 8 This is a schematic diagram of a circuit board 200, a DC copper busbar 103, and pins 301 provided in an embodiment of this application.

[0079] In one embodiment, see [reference] Figure 8 The circuit board 200 includes a first conductive layer 201 and a second conductive layer 202. The first conductive layer 201 and the second conductive layer 202 are used to transmit DC power. The DC copper bus 103 is used to connect the first conductive layer 201 or the second conductive layer 202. The pin 301 is used to connect the first conductive layer 201 or the second conductive layer 202.

[0080] In this embodiment, the first conductive layer 201 and the second conductive layer 202 are used to transmit DC power between the power module 100 and the capacitor 300, so that DC power between the power module 100 and the multiple capacitors 300 can be transmitted through the circuit board 200.

[0081] In one embodiment, one of the first conductive layer 201 and the second conductive layer 202 is connected to the positive electrode, and the other of the first conductive layer 201 and the second conductive layer 202 is connected to the negative electrode.

[0082] In one embodiment, since the power of the DC current transmitted by the first conductive layer 201 and the second conductive layer 202 is greater than the power of the signal transmitted by the signal transmission layer in the circuit board 200, the width of the first conductive layer 201 and the second conductive layer 202 is greater than the width of the signal transmission layer in the circuit board 200. Alternatively, the area of ​​the first conductive layer 201 and the second conductive layer 202 is greater than the area of ​​the signal transmission layer in the circuit board 200.

[0083] In one embodiment, the first conductive layer 201 or the second conductive layer 202 may be distributed inside the circuit board 200, or at least one of the first conductive layer 201 and the second conductive layer 202 may be distributed on the surface of the circuit board 200. In one embodiment, the first conductive layer 201 and the second conductive layer 202 are arranged alternately along the second direction Z.

[0084] In one embodiment, the DC busbar 103 of the power module 100 can be plugged into the circuit board 200, or the DC busbar 103 of the power module 100 can be soldered to the circuit board 200.

[0085] In one embodiment, the pin 301 of each capacitor 300 can be plugged into the circuit board 200, or the pin 301 of each capacitor 300 can be soldered to the circuit board 200.

[0086] In one embodiment, combined with Figures 4 to 7 The motor controller 10 also includes a DC connection copper busbar 500, which is used to transmit DC power between multiple capacitors 300 and the power battery 13. Specifically, DC busbars 103 are distributed along a first direction X on the side of the multiple capacitors 300 facing away from the power module 100. A circuit board 200 is stacked along a second direction Z on the power module 100, the multiple capacitors 300, and the DC busbars 103. The DC connection copper busbar 500 faces the circuit board 200 and is used for electrical connection to the circuit board 200.

[0087] In this embodiment, the solution shortens the internal current transmission path of the motor controller 10, reduces impedance, and reduces heat generation. By transmitting DC power between the capacitor 300 and the DC connection copper busbar 500 through the circuit board 200 via the DC connection copper busbar 500, the copper busbar between multiple capacitors 300 and the DC copper busbar 103 is eliminated, reducing volume and impedance. Furthermore, the arrangement of the DC connection copper busbar 500, multiple capacitors 300, and power module 100 in this solution shortens the power flow path between the DC connection channel and the power module 100, reducing impedance and heat generation.

[0088] In one embodiment, the DC connection copper busbar 500 is inserted into the circuit board 200, simplifying the installation method between the circuit board 200 and the DC connection copper busbar 500. In another embodiment, the DC connection copper busbar 500 is soldered to the circuit board 200.

[0089] In one embodiment, the DC connection copper bus 500 is electrically connected to the first conductive layer 201 and the second conductive layer 202 in the circuit board 200, so that the DC power transmitted by the DC connection copper bus 500 is transmitted in the circuit board 200.

[0090] In one embodiment, the DC connection copper busbar 500 includes two copper busbars 501, one of which is used to electrically connect to the first conductive layer 201, and the other of which is used to electrically connect to the second conductive layer 202.

[0091] In one embodiment, when the motor controller 10 is used to generate electricity to charge the power battery 13, when the motor controller 10 acts as a generator controller, the power module 100 is used to convert AC power into DC power, the DC bus 103 is used to transmit the DC power from the power module 100 to the circuit board 200 along the second direction Z, the DC power transmitted to the circuit board 200 flows in the circuit board 200 along a plane perpendicular to the second direction Z, the pin 301 is used to transmit the DC power output from the circuit board 200 to multiple capacitors 300 along the second direction Z, the multiple capacitors 300 adjust the received DC power and transmit it back to the circuit board 200, the DC connection bus 500 receives the DC power in the circuit board 200 after being adjusted by the multiple capacitors 300 along the second direction Z and transmits the DC power to the power battery 13 to charge the power battery 13.

[0092] In this embodiment of the application, the solution is used to shorten the current transmission path between the power module 100, circuit board 200, multiple capacitors 300 and DC connection copper busbar 500 during power generation, thereby achieving the technical effect of reducing impedance and reducing the size of motor controller 10 during power generation.

[0093] In this embodiment, the power flow path from the power module 100 to the DC connection copper busbar 500 flows along the first direction X in a plane perpendicular to the second direction Z, thus shortening the power flow path.

[0094] In one embodiment, when the motor controller 10 controls the drive motor 50, the DC bus 500 transmits the DC power output from the power battery 13 along the second direction Z to the circuit board 200. The circuit board 200 transmits the DC power received through the DC bus 500 along the second direction Z to multiple capacitors 300. After adjustment, the multiple capacitors 300 transmit the DC power through pins 301 along the second direction Z to the circuit board 200. The DC power transmitted to the circuit board 200 flows again within the circuit board 200 in a plane perpendicular to the second direction Z. The DC bus 103 transmits the DC power output from the circuit board 200 along the second direction Z to the power module 100. The power module 100 converts the DC power into AC power and transmits it to the drive motor 50.

[0095] In this embodiment of the application, the solution is used to shorten the current transmission path between the DC connection copper busbar 500, multiple capacitors 300, circuit board 200 and power module 100 in the driving state, thereby achieving the technical effect of reducing impedance and reducing the size of motor controller 10 in the driving state.

[0096] In one embodiment, see [reference] Figure 6 and Figure 7 The DC connection copper busbar 500 is also used to pass through the magnetic ring 600, which is used to filter the DC transmitted by the DC connection copper busbar 500.

[0097] Figure 9 yes Figure 6 Enlarged view of section M in the middle.

[0098] In one embodiment, see [reference] Figure 9 The power module 100 includes two DC copper busbars 103. Each DC copper busbar 103 includes a connecting section 1031 and a bending section 1032. One end of the connecting section 1031 extends out of the power module 100 along a first direction X. The bending section 1032 is distributed at one end of the connecting section 1031 along the first direction X. The connecting sections 1031 of the two DC copper busbars 103 are stacked at intervals along a second direction Z. The bending section 1032 is bent toward the circuit board 200 relative to the connecting section 1031. The bending section 1032 is used to insert into and electrically connect to the circuit board 200. The bending sections 1032 of the two DC copper busbars 103 are spaced apart along the first direction X.

[0099] In this embodiment, the solution is used to reduce the stray inductance of the DC copper busbar 103 and avoid electrical interference, thereby effectively reducing the stray inductance of the power circuit in the motor controller 10 and improving the stability of the motor controller 10. Since the two DC copper busbars 103 need to be electrically connected to the circuit board 200, the connection to the circuit board 200 is made more convenient by bending the bent section 1032 toward the circuit board 200. By stacking the connecting sections 1031 at intervals in the second direction Z and the bent sections 1032 at intervals in the first direction X, both the stray inductance of the DC copper busbar 103 and electrical interference are taken into account.

[0100] In this embodiment, since the circuit board 200 needs to be stacked on the power module 100 and multiple capacitors 300 to reduce the size in the second direction Z, by extending the connecting segment 1031 out of the power module 100 along the first direction X, the connecting segment 1031 occupies a small size in the second direction Z. However, this makes it inconvenient for the DC copper busbar 103 to connect to the circuit board 200 stacked on top of the power module 100. By bending the bent segment 1032 distributed on the side of the connecting segment 1031 away from the power module 100 toward the circuit board 200, it is more convenient for the circuit board 200 to insert the bent segment 1032.

[0101] In one embodiment, the power module 100 includes two DC busbars 103, one for connecting to the positive terminal and the other for connecting to the negative terminal. Each DC busbar 103 electrically connects all power modules 102 of the power module 100. See also: Figure 7 The power module 100 includes three power modules 102, a DC copper busbar 103 is stacked on the upper surface of the three power modules 102 along the second direction Z, another DC copper busbar 103 extends from the side of the three power modules 100 along the first direction X, and the connecting section 1031 of the two DC copper busbars 103 is stacked at intervals along the second direction Z on the outside of the side of the power module 100.

[0102] In one embodiment, combined with Figure 6 and Figure 9 The power module 100 includes a package structure 104 and a power switch structure packaged inside it. At least one DC copper busbar 103 is stacked on the surface of the package structure 104 along the second direction Z and extends out of the power module 100 along the first direction X. Alternatively, the DC copper busbar 103 extends out of the package structure 104 from the side of the package structure 104 along the first direction X.

[0103] Figure 10 yes Figure 7 A magnified view of section N. Figure 11 This is a schematic diagram of a power module 100 provided in an embodiment of this application.

[0104] In one embodiment, combined with Figure 9 , Figure 10 and Figure 11 The bent sections 1032 of the two DC copper busbars 103 are staggered along the third direction Y. The third direction Y is perpendicular to the first direction X and the second direction Z. The distance between the bent sections 1032 of the two DC copper busbars 103 along the third direction Y is greater than the distance between the bent sections 1032 of the two DC copper busbars 103 along the first direction X.

[0105] In the embodiments of this application, combined with Figure 9 and Figure 11 The distance between the bent sections 1032 of the two DC copper busbars 103 along the third direction Y is denoted as L1, and the distance between the bent sections 1032 of the two DC copper busbars 103 along the first direction X is denoted as L2, and L1 is greater than L2.

[0106] In this embodiment, the solution achieves both reduced size of the motor controller 10 and improved electrical isolation. By offsetting the two bent segments 1032 along the third direction Y and ensuring that the distance between them in the third direction Y is greater than the distance in the first direction X, electrical isolation is achieved while maintaining a small footprint.

[0107] In this embodiment, the two bent segments 1032 are staggered along the third direction Y, thereby improving the electrical isolation between them. Since the staggering of the two bent segments 1032 in the third direction Y satisfies the condition for electrical isolation, and by making the distance between the two bent segments 1032 in the third direction Y greater than the distance in the first direction X, the two DC copper busbars 103 occupy a smaller size in the first direction X. This allows for more space inside the motor controller 10 to arrange other components, or makes the power module 100 more compactly arranged with other components, which helps to reduce the size of the motor controller 10.

[0108] In one embodiment, combined with Figure 7 and Figure 10 Two DC copper busbars 103 and multiple capacitors 300 are arranged at intervals along the first direction X. The bent sections 1032 of the two DC copper busbars 103 along the first direction X are distributed between the connecting section 1031 and the multiple capacitors 300.

[0109] In this embodiment, the bent section 1032 is distributed between the connecting section 1031 and the multiple capacitors 300, so that the bent section 1032 and the multiple capacitors 300 are closer together. This helps to shorten the distance between the first conductive layer 201 and the second conductive layer 202 connecting the bent section 1032 and the multiple capacitors 300 in the circuit board 200, thereby improving the current transmission effect and reducing the impedance.

[0110] In one embodiment, by having two bent segments 1032 staggered along a third direction Y and the spacing in the third direction Y being greater than the spacing in the first direction X, the size of the power module 100 and the multiple capacitors 300 after assembly along the first direction X is small, which is beneficial to reducing the volume of the motor controller 10.

[0111] Figure 12 This is another schematic diagram of the internal components of the motor controller 10 provided in the embodiments of this application.

[0112] In one embodiment, see [reference] Figure 12The multiple capacitors 300 include a bus capacitor 310. Bent sections 1032 of two DC busbars 103 along a first direction X are distributed between a connecting section 1031 and the bus capacitor 310. The bus capacitor 310 includes multiple pins 301. The bus capacitor 310 includes two first sides 311 along the first direction X and two second sides 312 arranged opposite each other along a third direction Y. The two first sides 311 are denoted as one first side 311a and the other first side 311b. The two DC busbars 103 of the power module 100 are adjacent to one first side 311a along the first direction X. The distance between each pin 301 of the bus capacitor 310 and one first side 311a along the first direction X is greater than the distance between any pin 301 of the bus capacitor 310 and an adjacent second side 312 along the third direction Y.

[0113] In this embodiment of the application, the distance between each pin 301 of the bus capacitor 310 and a first side 311a along the first direction X is denoted as L3, and the distance between any pin 301 of the bus capacitor 310 and a second side 312 adjacent to it along the third direction Y is denoted as L4, where L3 > L4.

[0114] In this embodiment, the bus capacitor 310 is used to filter out low-frequency ripple, stabilize the DC bus voltage, and provide smooth DC power to the power module 100.

[0115] In this embodiment, since the bus capacitor 310 is adjacent to the DC copper busbar 103 of the power module 100, the pins 301 of the bus capacitor 310 are distributed away from a first side 311 near the bend section 1032 to avoid interference between the pins 301 of the bus capacitor 310 and the DC copper busbar 103 when the bus capacitor 310 is inserted into the circuit board 200, thereby improving the electrical isolation effect.

[0116] In one embodiment, combined with Figure 6 , Figure 8 and Figure 12 The multiple capacitors 300 include a Y capacitor 320, which has two pins 301. One pin 301 of the Y capacitor 320 is used to electrically connect to a DC copper busbar 103 of the power module 100 through the circuit board 200, and the other pin 301 of the Y capacitor 320 is used to electrically connect to the ground plane 203 within the circuit board 200.

[0117] In this embodiment, the Y capacitor 320 is used to filter out common-mode interference, improve the filtering effect of the switching frequency band, and enhance the EMC performance of the motor controller 10. The Y capacitor 320 connects to a DC copper busbar 103 of the power module 100 and the ground plane 203 through the circuit board 200 via two pins 301, which reduces impedance compared to connecting the Y capacitor 320 to the power module 100 via a copper busbar.

[0118] In one embodiment, combined with Figure 8 and Figure 12 One pin 301 of the Y capacitor 320 is inserted into the circuit board 200 and connected to the first conductive layer 201 or the second conductive layer 202 in the circuit board 200. The other pin 301 of the Y capacitor 320 is inserted into the circuit board 200 and connected to the ground layer 203 in the circuit board 200.

[0119] In one embodiment, the plurality of capacitors 300 includes two Y capacitors 320. One pin 301 of one Y capacitor 320 is inserted into the circuit board 200 to connect to the first conductive layer 201 in the circuit board 200. One pin 301 of the other Y capacitor 320 is inserted into the circuit board 200 to connect to the second conductive layer 202 in the circuit board 200. The other pin 301 of both Y capacitors 320 is inserted into the circuit board 200 to connect to the ground layer 203 in the circuit board 200. This achieves filtering of the positive and negative currents transmitted through the first conductive layer 201 and the second conductive layer 202.

[0120] In one embodiment, two Y capacitors 320 are used to filter out low-frequency common-mode interference, improving the EMC performance of the motor controller 10.

[0121] In one embodiment, any one of the ground layer 203, the first conductive layer 201, and the second conductive layer 202 of the circuit board 200 is a metal layer. In another embodiment, any one of the ground layer 203, the first conductive layer 201, and the second conductive layer 202 is a copper layer.

[0122] In one embodiment, see again Figure 4 The circuit board 200 includes a mounting hole 204, and the motor controller 10 includes a fastener (not shown). The fastener is used to pass through the mounting hole 204 to fix the circuit board 200 and the housing 400 of the motor controller 10. The fastener is used to electrically connect the ground layer 203 of the circuit board 200 and the housing 400 of the motor controller 10. In this embodiment, the Y capacitor 320 is grounded by electrically connecting the fixing member in the fixing hole 204 of the circuit board 200 to the grounding layer 203 in the circuit board 200, thus reusing the fixing hole 204 and simplifying the grounding structure.

[0123] In one embodiment, the fastener includes a screw (not shown), the housing 400 of the motor controller 10 includes a screw hole, and a portion of the ground layer 203 of the circuit board 200 is exposed on the inner wall of the fixing hole 204, such that when the screw is inserted into the fixing hole 204 of the circuit board 200 and connected to the screw hole of the housing 400 of the motor controller 10, the screw can connect the portion of the ground layer 203 exposed in the fixing hole 204 and the housing 400, thereby realizing the electrical connection of the ground layer 203 of the circuit board 200 to the housing 400 of the motor controller 10, and achieving grounding.

[0124] In one embodiment, the grounding layer 203 is connected to the housing 400 of the motor controller 10 through multiple low-impedance screw vias, achieving a large-area, short-path connection and reducing high-frequency grounding impedance.

[0125] In one embodiment, see [reference] Figure 12 The plurality of capacitors 300 includes two bus capacitors 310 and two Y capacitors 320. The two bus capacitors 310 are denoted as bus capacitor 310a and bus capacitor 310b, respectively, and the two Y capacitors 320 are denoted as Y capacitor 320a and Y capacitor 320b, respectively. The two bus capacitors 310 are arranged adjacent to each other along the third direction Y. One Y capacitor 320a is distributed on one side of the two bus capacitors 310 along the third direction Y. One Y capacitor 320a is arranged sequentially adjacent to the two bus capacitors 310 along the third direction Y. The other Y capacitor 320b is distributed along the first direction X on the side of the bus capacitors 310b away from the power module 100. The DC connection copper busbar 500 and the other Y capacitor 320b are arranged alternately along the third direction Y. The length direction of each bus capacitor 310 is parallel to the third direction Y, and the width direction of each bus capacitor 310 is parallel to the first direction X. One Y capacitor 320a has its length direction parallel to the first direction X, and its length is less than the width of each bus capacitor 310. Another Y capacitor 320b has its length direction parallel to the third direction Y, and its length is less than the length of its adjacent bus capacitor 310b.

[0126] In one embodiment, see [reference] Figure 12 The DC connection copper busbar 500 includes two copper busbars 501, which are inserted into the circuit board 200. The two copper busbars 501 are spaced apart along a third direction Y, and their thickness direction is parallel to the first direction X. The two copper busbars 501 along the third direction Y are distributed on the side of another Y capacitor 320b near a Y capacitor 320a. The two copper busbars 501 are arranged adjacent to the bus capacitor 310a along the first direction X.

[0127] In this embodiment, the design of the power module 100, bus capacitor 310, Y capacitor 320 and DC connection copper bus 500 achieves a compact layout while facilitating the quick installation of the circuit board 200 with the power module 100, bus capacitor 310, Y capacitor 320 and DC connection copper bus 500. It also shortens the power flow transmission path, reduces impedance and noise, improves the stability of the motor controller 10 and optimizes NVH performance.

[0128] In one embodiment, see again Figure 8The circuit board 200 includes a first conductive layer 201, a ground layer 203, and a second conductive layer 202. Along a second direction Z, the first conductive layer 201, ground layer 203, and second conductive layer 202 are arranged sequentially at intervals. The first conductive layer 201 and the second conductive layer 202 are used to transmit direct current, and the ground layer 203 is used to electrically connect to the housing 400 of the motor controller 10. The first conductive layer 201 and the ground layer 203 are used to filter out common-mode interference generated by the power module 102, and the second conductive layer 202 and the ground layer 203 are also used to filter out common-mode interference generated by the power module 102.

[0129] In this embodiment, the solution reuses two conductive layers 201 and 202 (for transmitting DC current) and a ground layer 203 to form an equivalent Y capacitor and reduce impedance. This improves the filtering effect on the current in the motor controller 10 and significantly increases the insertion loss of the equivalent Y capacitor, reducing its equivalent impedance at high frequencies. Consequently, it achieves insertion loss far superior to traditional solutions in the critical risk frequency band of 30MHz to 80MHz, effectively suppressing electromagnetic interference. Furthermore, it reduces the number of Y capacitors inserted into the circuit board 200, decreasing the size of the motor controller 10, simplifying the installation process, and improving production efficiency.

[0130] In one embodiment, the first conductive layer 201 and the ground layer 203 are used to filter out high-frequency common-mode interference generated by the power module 102, and the second conductive layer 202 and the ground layer 203 are used to filter out high-frequency common-mode interference generated by the power module 102, preventing high-frequency noise from propagating along the DC bus.

[0131] In one embodiment, the two Y capacitors 320 of the motor controller 10 are used to filter out low-frequency common-mode interference generated by the power module 102. The high-frequency interference is higher than the low-frequency interference.

[0132] In this embodiment, the first conductive layer 201, the second conductive layer 202 and the ground layer 203 form an equivalent Y capacitor and two Y capacitors 320 work together to filter out high-frequency common-mode interference and low-frequency common-mode interference generated by the power module 102. The two are combined to form a wideband composite filter network, which improves the filtering effect, enhances the stability of the motor controller 10 and optimizes NVH performance.

[0133] In this embodiment, the areas of the first conductive layer 201, the second conductive layer 202, and the ground layer 203 in the circuit board 200 are larger than those of the signal transmission layer. By reducing the interlayer thickness between any two of the first conductive layer 201, the second conductive layer 202, and the ground layer 203, an equivalent Y capacitor with a multilayer structure is constructed. By precisely controlling the interlayer dielectric thickness and utilizing the parallel plate capacitor principle, a small-capacitance Y capacitor with extremely low parasitic inductance can be directly constructed using the circuit board 200, which is equivalent to a low-impedance, small-capacitance Y capacitor.

[0134] Figure 13 This is another schematic diagram of the power module 100 provided in the embodiments of this application.

[0135] In one embodiment, see [reference] Figure 13 The power module 100 is used to convert AC power to DC power, and multiple capacitors 300 are used to adjust the DC power and transmit it to the power battery 13 to charge the power battery 13. The power module 100 includes a fast recovery diode 107 and an insulated gate bipolar transistor 105. The area of ​​the fast recovery diode 107 is larger than the area of ​​the insulated gate bipolar transistor 105.

[0136] In this embodiment, the motor controller 10 is used for power generation, and the motor controller 10 serves as a generator controller. This solution balances meeting power generation requirements with cost reduction. During power generation, the power required by the insulated-gate bipolar transistor 105 in the motor controller 10 is relatively small; by reducing the area of ​​the insulated-gate bipolar transistor 105, power generation requirements can be met while simultaneously reducing costs.

[0137] In one embodiment, combined with Figure 4 and Figure 6 The power module 100 includes multiple signal pins 101, which are used to transmit signals and are used to insert into and electrically connect to the circuit board 200. The orientation of the DC busbar 103 along the second direction Z is the same as the orientation of the multiple signal pins 101 of the power module 100.

[0138] In this embodiment of the application, multiple signal pins 101 of the power module 100 are electrically connected to the signal transmission layer of the circuit board 200 to transmit signals.

[0139] In this embodiment, by aligning the DC busbar 103 with the signal pins 101 of the power module 100, the DC busbar 103 is inserted simultaneously with the power module 100 signal pins 101 inserted along the second direction Z, thus simplifying the installation.

[0140] In one embodiment, see [reference] Figure 7 Multiple signal pins 101 of the power module 100 and the bent section 1032 of the DC copper busbar 103 are distributed on both sides of the power module 100 to avoid mutual interference between the signal transmitted by the signal pins 101 and the current transmitted by the bent section 1032 of the DC copper busbar 103.

[0141] In one embodiment, see again Figure 7The power module 100 includes multiple AC copper busbars 106 for transmitting AC power. The multiple AC copper busbars 106 and the bent sections 1032 of the DC copper busbars 103 are distributed on both sides of the power module 100.

[0142] In one embodiment, see again Figure 7 Multiple AC copper busbars 106 are electrically connected to the generator 20 or the drive motor 50 via adapter 700.

[0143] In one embodiment, when the motor controller 10 is used to generate electricity, the AC busbar 106 is used to electrically connect the generator 20 to receive AC power.

[0144] In one embodiment, when the motor controller 10 controls the drive motor 50 to drive, the AC bus 106 is used to electrically connect the drive motor 50 to transmit AC power to control the drive motor 50.

[0145] In one embodiment, multiple AC busbars 106 are electrically connected to a circuit board 200, through which AC power is transmitted. Transmitting AC power through the circuit board 200 reduces the number of copper busbars, thereby lowering impedance and unwanted inductance.

[0146] In one embodiment, see again Figure 4 The housing 400 of the motor controller 10 includes a bottom shell 410 and a cover plate 420. The cover plate 420 is stacked on the bottom shell 410 along the second direction Z and surrounds the opening 411 of the bottom shell 410. The bottom shell 410 is used to fix the circuit board 200, the power module 100 and multiple capacitors 300. The circuit board 200 is stacked on the side of the power module 100 and multiple capacitors 300 away from the bottom shell 410 along the second direction Z. The cover plate 420 is stacked on the side of the circuit board 200 away from the power module 100 and multiple capacitors 300 along the second direction Z.

[0147] In this embodiment, since the power module 100 and multiple capacitors 300 are fixed to the circuit board 200, and the circuit board 200 is stacked on the power module 100 and multiple capacitors 300 along the second direction Z, the mounting direction of the circuit board 200 and the cover plate 420 is consistent, the assembly direction is unified, and the process is simplified.

[0148] In one embodiment, see again Figure 6 The motor controller 10 includes at least one heat sink 800, which is distributed below the power module 100, above the circuit board 200, or below a plurality of capacitors 300, such that the heat sink 800 can be used for at least one of the power module 100, the circuit board 200, and the plurality of capacitors 300.

[0149] In this embodiment, since the power module 100 and multiple capacitors 300 are electrically connected through the circuit board 200, the circuit board 200 generates a high amount of heat. The power module 100, the circuit board 200 and multiple capacitors 300 are cooled by the heat sink 800, thereby reducing the size of the motor controller, reducing the current transmission impedance and reducing the interference inductance, while reducing the operating temperature of the motor controller 10 and improving the operating efficiency of the motor controller 10.

[0150] The motor controller, electric drive assembly, and electric vehicle provided in the embodiments of this application have been described in detail above. Specific examples have been used to illustrate the principles and embodiments of this application. The description of the embodiments above is only for the purpose of helping to understand the method and core ideas of this application. At the same time, for those skilled in the art, there will be changes in specific embodiments and application scope based on the ideas of this application. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A motor controller, characterized in that, The motor controller includes a circuit board, a power module, and multiple capacitors. The power module is used to convert between AC and DC power. The multiple capacitors are used to adjust the DC power and transmit it to the power battery to charge the power battery, or to adjust the DC power output from the power battery and transmit it to the power module. The circuit board is used to transmit signals to drive the power module. The power module and the plurality of capacitors are arranged in a flat layout along a first direction, and the circuit board is stacked on top of the power module and the plurality of capacitors along a second direction, wherein the first direction is perpendicular to the second direction; the power module includes a DC busbar, and each capacitor includes a pin, wherein the pin and the DC busbar both face the circuit board and are used to electrically connect to the circuit board; the DC busbar is used to transmit the DC power output from the power module to the circuit board or to transmit the DC power transmitted from the circuit board to the power module; the pin is used to receive the DC power transmitted from the circuit board and transmit the DC power to the plurality of capacitors or to transmit the DC power adjusted by the plurality of capacitors to the circuit board.

2. The motor controller according to claim 1, characterized in that, The DC busbar is used to transmit the DC power along the second direction between the power module and the circuit board. The DC power transmitted to the circuit board flows in a plane perpendicular to the second direction within the circuit board. The pins are used to transmit the DC power along the second direction between the circuit board and the plurality of capacitors.

3. The motor controller according to claim 1 or 2, characterized in that, The motor controller also includes a DC connection copper busbar, which is used to transmit DC power between the plurality of capacitors and the power battery, wherein: The DC busbars are distributed along the first direction on the side of the plurality of capacitors away from the power module. The circuit board is stacked along the second direction on the power module, the plurality of capacitors and the DC connection busbars. The DC connection busbars face the circuit board and are used to electrically connect the circuit board.

4. The motor controller according to any one of claims 1-3, characterized in that, The power module includes two DC copper busbars, each DC copper busbar including a connecting section and a bending section. One end of the connecting section extends out of the power module along the first direction, and the bending section is distributed at one end of the connecting section along the first direction. The connecting sections of the two DC copper busbars are stacked at intervals along the second direction. The bending section bends towards the circuit board relative to the connecting section. The bending section is used to insert into and electrically connect to the circuit board. The bending sections of the two DC copper busbars are spaced apart along the first direction.

5. The motor controller according to claim 4, characterized in that, The bent sections of the two DC copper busbars are staggered along a third direction, which is perpendicular to the first direction and the second direction. The distance between the bent sections of the two DC copper busbars along the third direction is greater than the distance between the bent sections of the two DC copper busbars along the first direction.

6. The motor controller according to claim 4, characterized in that, The two DC copper busbars and the plurality of capacitors are arranged at intervals along the first direction, and the bent sections of the two DC copper busbars are distributed between the connecting section and the plurality of capacitors along the first direction.

7. The motor controller according to any one of claims 1-6, characterized in that, The plurality of capacitors includes a bus capacitor, the bus capacitor includes a plurality of pins, the bus capacitor includes two first sides along the first direction and two second sides arranged opposite to each other along a third direction, the third direction being perpendicular to the first direction and the second direction, and the two DC copper busbars of the power module along the first direction are adjacent to one of the first sides, wherein: The distance between each pin of the bus capacitor and the first side along the first direction is greater than the distance between any pin of the bus capacitor and the adjacent second side along the third direction.

8. The motor controller according to any one of claims 1-7, characterized in that, The plurality of capacitors includes a Y capacitor, the Y capacitor having two pins, one pin of the Y capacitor being used to electrically connect to a DC busbar of the power module via the circuit board, and the other pin of the Y capacitor being used to electrically connect to the ground plane within the circuit board.

9. The motor controller according to claim 8, characterized in that, The circuit board includes a mounting hole, and the motor controller includes a fixing member. The fixing member is used to pass through the mounting hole to fix the circuit board and the housing of the motor controller. The fixing member is used to electrically connect the ground layer of the circuit board and the housing of the motor controller.

10. The motor controller according to any one of claims 1-9, characterized in that, The circuit board includes a first conductive layer, a ground layer, and a second conductive layer. The first conductive layer, the ground layer, and the second conductive layer are arranged sequentially at intervals along the second direction. The first conductive layer and the second conductive layer are used to transmit the direct current, and the ground layer is used to electrically connect to the housing of the motor controller. The first conductive layer and the ground layer are used to filter out common-mode interference generated by the power module, and the second conductive layer and the ground layer are used to filter out common-mode interference generated by the power module.

11. The motor controller according to any one of claims 1-10, characterized in that, The power module is used to convert the alternating current into direct current. The multiple capacitors are used to adjust the direct current and transmit it to the power battery to charge the power battery. The power module includes a fast recovery diode and an insulated gate bipolar transistor. The area of ​​the fast recovery diode is larger than the area of ​​the insulated gate bipolar transistor.

12. The motor controller according to any one of claims 1-11, characterized in that, The power module includes multiple signal pins for transmitting signals. The multiple signal pins of the power module are used to insert into and electrically connect to the circuit board. The orientation of the DC copper busbar along the second direction is the same as the orientation of the multiple signal pins of the power module.

13. The motor controller according to any one of claims 1-12, characterized in that, The housing of the motor controller includes a bottom shell and a cover plate. The cover plate is stacked on the bottom shell along the second direction and surrounds the opening of the bottom shell. The bottom shell is used to fix the circuit board, the power module, and the plurality of capacitors. The circuit board is stacked on the side of the power module and the plurality of capacitors away from the bottom shell along the second direction. The cover plate is stacked on the side of the circuit board away from the power module and the plurality of capacitors along the second direction.

14. An electric drive assembly, characterized in that, The electric drive assembly includes a generator and a motor controller as described in any one of claims 1-13, wherein the power module of the motor controller is electrically connected to the generator to receive AC power; or The electric drive assembly includes a drive motor and a motor controller as described in any one of claims 1-13, wherein the power module of the motor controller is used to convert the direct current transmitted from the power battery into alternating current and then transmit it to the drive motor.

15. An electric vehicle, characterized in that, The electric vehicle includes a power battery and an electric drive assembly as described in claim 14, the electric drive assembly being used to charge the power battery or to drive the wheels of the electric vehicle.

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