A six-phase generator controller and generator assembly

Abstract

The application discloses a six-phase generator controller and a generator assembly. The controller comprises a first end plate, a second end plate, a cylindrical shell, a supporting capacitor assembly, a DC connection part, a six-phase AC connection part and a plurality of power modules. The supporting capacitor assembly is located in the shell and is provided with a plurality of module mounting parts distributed in the circumferential direction; the plurality of power modules are arranged in the plurality of module mounting parts and are located between the supporting capacitor assembly and the shell, wherein a part constitutes a first three-phase power conversion unit and another part constitutes a second three-phase power conversion unit. The supporting capacitor assembly comprises a capacitor body and a DC bus, the DC bus is electrically connected with the DC connection part and the DC end of the plurality of power modules respectively, and the six-phase AC connection part is electrically connected with the AC end of the two three-phase power conversion units. The generator assembly comprises a generator and the above controller, and the second end plate is connected with the end cover of the generator. The application can utilize the circumferential space in the shell to accommodate the components required for six-phase electric energy conversion.

Description

Technical Field

[0001] This invention relates to the field of generators, and in particular to a six-phase generator controller and generator assembly. Background Technology

[0002] With the development of low-altitude aircraft and hybrid power generation systems, the power levels of airborne power generation systems are gradually increasing. The generator controller is used to convert the AC output of the generator into electrical energy between the AC and DC buses. To improve power redundancy, aircraft generators often employ two sets of three-phase windings; therefore, the matching controller needs to accommodate power devices and DC support components corresponding to the six-phase power conversion.

[0003] Existing six-phase generator controllers typically have power devices, supporting capacitors, and connecting components arranged in a planar manner, housed in a box-type enclosure. When the controller is installed at the generator end, the arrangement of its internal components is difficult to match with the available space at the generator end, and additional space needs to be reserved between the components for installation and connection, resulting in a large space occupied by the controller and hindering the combined installation of the controller and generator.

[0004] Therefore, how to accommodate the power devices and DC support components required for six-phase power conversion within the limited installation space at the generator end is a technical problem that needs to be solved in this field. Summary of the Invention

[0005] In view of the above, it is necessary to provide a six-phase generator controller and generator assembly to solve the problem that existing generator controllers cannot accommodate the components required for six-phase power conversion within the limited space at the generator end.

[0006] To achieve the above objectives, the present invention provides a six-phase generator controller, comprising a first end plate, a second end plate, a housing, a supporting capacitor assembly, a DC connection portion, a six-phase AC connection portion, and multiple power modules. The housing is cylindrical, and the first and second end plates are respectively connected to the axial ends of the housing. The supporting capacitor assembly is located inside the housing and has multiple module mounting portions distributed circumferentially. The multiple power modules are disposed in the multiple module mounting portions and located between the supporting capacitor assembly and the housing. A portion of the multiple power modules constitutes a first three-phase power conversion unit, and another portion constitutes a second three-phase power conversion unit. The supporting capacitor assembly includes a capacitor body and a DC busbar electrically connected to the capacitor body. The DC busbar is electrically connected to the DC connection portion and the DC terminals of the multiple power modules, and the six-phase AC connection portion is electrically connected to the AC terminals of the first and second three-phase power conversion units.

[0007] In some embodiments, the housing is cylindrical. The supporting capacitor assembly also includes a capacitor housing extending axially along the housing, the capacitor housing being polygonal in shape and having a plurality of outer side surfaces sequentially connected circumferentially. Multiple module mounting portions are formed on the multiple outer side surfaces, and the capacitor body and DC bus are disposed within the capacitor housing.

[0008] In some embodiments, the capacitor casing is hexagonal prism-shaped and has six outer surfaces. There are six module mounting portions and six power modules, with the six module mounting portions formed on the six outer surfaces and the six power modules disposed on the six module mounting portions. Three of the six power modules constitute a first three-phase power conversion unit, and the other three constitute a second three-phase power conversion unit.

[0009] In some embodiments, the supporting capacitor assembly includes a liquid inlet, a liquid outlet, and multiple cooling channels. Each cooling channel corresponds to a specific module mounting portion, with each channel located on the side of the corresponding module mounting portion opposite to the power module and extending along the corresponding module mounting portion. The multiple cooling channels connect the liquid inlet and the liquid outlet, and the power module has a heat dissipation surface facing the corresponding module mounting portion, which is in contact with the corresponding module mounting portion.

[0010] In some embodiments, the DC bus includes a positive conductive layer, a negative conductive layer, and an insulating layer, with the insulating layer sandwiched between the positive and negative conductive layers. The positive conductive layer has a positive input terminal and multiple positive output terminals, and the negative conductive layer has a negative input terminal and multiple negative output terminals. Each positive output terminal and one negative output terminal form a set of DC output terminals, and multiple sets of DC output terminals correspond one-to-one with multiple power modules. The positive and negative output terminals of each set of DC output terminals are electrically connected to the positive and negative DC terminals of the corresponding power module, respectively.

[0011] In some embodiments, the capacitor housing has a plurality of first support posts at one end along the axial direction of the outer casing, and a plurality of second support posts at the other end along the axial direction of the outer casing. The plurality of first support posts are spaced apart circumferentially around the capacitor housing and are respectively connected to a first end plate. The plurality of second support posts are spaced apart circumferentially around the capacitor housing and are respectively connected to a second end plate. Each power module is located between the plurality of first support posts and the plurality of second support posts.

[0012] In some embodiments, the DC connection includes a DC connector mounted on the first end plate, and the six-phase generator controller further includes a DC filter. The DC filter is disposed at the end of the supporting capacitor assembly facing the first end plate and is located between the DC connector and the DC busbar. The positive and negative input terminals of the DC filter are electrically connected to the positive and negative terminals of the DC connector, respectively, via bent copper busbars, and the positive and negative output terminals of the DC filter are electrically connected to the positive and negative input terminals of the DC busbar, respectively. The DC filter includes at least one inductor unit and at least two capacitor units disposed along the conductive path from the DC connector to the DC busbar.

[0013] In some embodiments, the six-phase AC connection includes six single-core AC connectors spaced circumferentially along the second end plate. The six-phase generator controller also includes six transition copper busbars, multiple current sensors, and at least one AC magnetic ring. One end of each transition copper busbar is electrically connected to an AC terminal of either the first or second three-phase power conversion unit, and the other end is electrically connected to a single-core AC connector. Multiple current sensors are respectively disposed on corresponding transition copper busbars. Six phase conductors connected to the six single-core AC connectors pass through at least one AC magnetic ring, which is disposed on the side of the second end plate facing the supporting capacitor assembly and adjacent to the housing.

[0014] In some embodiments, the six-phase generator controller further includes a main control board, multiple drive boards, a shielding cover, a resolver connector, a low-voltage connector, and an Ethernet connector. The multiple drive boards are respectively disposed on the side of the corresponding power module facing away from the supporting capacitor assembly, and are electrically connected to the main control board and the corresponding power module. The main control board is disposed at the end of the supporting capacitor assembly facing the second end plate, and the shielding cover is disposed on the side of the main control board facing away from the supporting capacitor assembly. The resolver connector, low-voltage connector, and Ethernet connector are all disposed on the first end plate. A wiring groove extending from the end where the main control board is located towards the first end plate is provided on the side of the supporting capacitor assembly, and the resolver connector, low-voltage connector, and Ethernet connector are respectively connected to the main control board through signal lines disposed in the wiring groove.

[0015] To achieve the above objectives, the present invention also provides a generator assembly, including a generator and a six-phase generator controller as described in any of the above embodiments. The generator includes an end cover, a first set of three-phase windings, and a second set of three-phase windings. A second end plate has multiple mounting holes, through which multiple fasteners pass and are connected to the end cover. The six-phase AC connection includes three first-phase terminals and three second-phase terminals. The three first-phase terminals are electrically connected to the three phase terminals of the first set of three-phase windings, and the three second-phase terminals are electrically connected to the three phase terminals of the second set of three-phase windings.

[0016] Compared with the above-mentioned background technology, the technical content provided by the present invention has at least the following technical effects.

[0017] In existing generator controllers, power devices, supporting capacitors, and their connecting components are typically distributed along a plane. When the controller needs to form two sets of three-phase power conversion units, the number of power devices increases, and the space required for each component to be deployed in the same direction also increases accordingly. Furthermore, the shape of the controller is not easily matched with the contour of the generator end.

[0018] In this invention, a supporting capacitor assembly is housed within a cylindrical outer casing, and multiple module mounting portions are arranged circumferentially thereon. Multiple power modules are respectively mounted in their corresponding module mounting portions. The supporting capacitor assembly is located inside the area enclosed by the multiple power modules, while the outer casing is located outside the multiple power modules, thus arranging the supporting capacitor assembly, the multiple power modules, and the outer casing sequentially in the radial direction. Multiple power modules that would normally need to be dispersed along a plane can be arranged around the supporting capacitor assembly, thereby utilizing the circumferential space between the supporting capacitor assembly and the outer casing and reducing the space occupied by multiple power modules deployed in a single direction.

[0019] The supporting capacitor assembly includes a capacitor body and a DC busbar, which is electrically connected to the DC connection section and the DC terminals of multiple power modules. Therefore, while located inside multiple power modules, the supporting capacitor assembly can also provide DC connections to multiple power modules, eliminating the need for long-distance connecting parts that cross the controller's interior between the capacitor body, the DC busbar, and the multiple power modules. This allows all components to be centrally located within the cylindrical housing.

[0020] A portion of the multiple power modules constitutes the first three-phase power conversion unit, and another portion constitutes the second three-phase power conversion unit. The two three-phase power conversion units are electrically connected to the six-phase AC connection section, respectively. Thus, the multiple power modules arranged circumferentially can form two sets of three-phase power conversion branches to connect the two sets of three-phase windings of the six-phase generator, enabling the controller to have the electrical connection relationships required for six-phase power conversion while adopting a cylindrical shape.

[0021] The first and second end plates are respectively connected to the axial ends of the housing, defining the mounting area for the supporting capacitor assembly and multiple power modules from both ends of the housing. After connecting the second end plate to the generator end cover, the six-phase generator controller can be installed at the generator end, and the six-phase AC connection part can be connected to the first and second sets of three-phase windings respectively. This helps to shorten the AC connection path between the generator windings and the controller, and reduces the additional installation space occupied by the controller, thereby improving the situation where existing generator controllers cannot accommodate the components required for six-phase power conversion within the limited space at the generator end. Attached Figure Description

[0022] To more clearly illustrate the relevant structures in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art 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 the provided drawings without any creative effort.

[0023] Figure 1 This is a schematic diagram of the overall structure of the six-phase generator controller provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the circuit topology of the six-phase generator controller provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of the supporting capacitor assembly provided in an embodiment of the present invention; Figure 4 This is a cross-sectional schematic diagram of the supporting capacitor assembly provided in an embodiment of the present invention; Figure 5 This is a schematic diagram of the structure of the shielding cover provided in an embodiment of the present invention; Figure 6 This is a schematic diagram of the structure of the AC magnetic ring and the second end plate provided in an embodiment of the present invention.

[0024] Explanation of reference numerals in the attached figures: 1. DC connector; 2. DC filter; 3. Support capacitor assembly; 31. Capacitor housing; 32. Capacitor body; 33. Module mounting section; 34. Cooling channel; 35. Wiring trough; 4. Power module; 41. First three-phase power conversion unit; 42. Second three-phase power conversion unit; 5. Current sensor; 6. AC magnetic ring; 7. Single-core AC connector; 8. Driver board; 9. Main control board; 10. First end board; 11. Adapter copper busbar; 12. Second end board; 13. Shielding cover; 14. Housing; 15. Resolver connector; 16. Low-voltage connector; 17. Ethernet connector; U1, V1 and W1, the first group of three-phase AC terminals; U2, V2 and W2, the second group of three-phase AC terminals. Detailed Implementation

[0025] The structure, connection relationships between components, and working process of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. The described embodiments are only some embodiments of the present invention, and not all embodiments. Other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are also within the protection scope of the present invention.

[0026] In the description of this invention, axial direction refers to the direction extending from the central axis of housing 14, circumferential direction refers to the direction surrounding the central axis of housing 14, and radial direction refers to the direction perpendicular to the central axis of housing 14 and toward or away from that central axis. The first end and the second end are only used to distinguish the two ends of housing 14 in the axial direction and do not indicate that the controller must be in a specific spatial orientation during assembly or use. The connection between the two components can be a direct connection or an indirect connection via fasteners, copper busbars, wires, terminals, or other intermediate components. Electrical connection between the two components can be achieved through copper busbars, wires, circuit board traces, or conductive terminals.

[0027] Please see Figure 1 and Figure 2 This invention provides a six-phase generator controller. The six-phase generator controller includes a first end plate 10, a second end plate 12, a housing 14, a supporting capacitor assembly 3, a DC connection portion, a six-phase AC connection portion, and multiple power modules 4. The housing 14 is cylindrical, and the first end plate 10 and the second end plate 12 are respectively connected to the two axial ends of the housing 14. The first end plate 10, the second end plate 12, and the housing 14 enclose an internal receiving space, within which the supporting capacitor assembly 3 and the multiple power modules 4 are located.

[0028] The supporting capacitor assembly 3 extends axially along the housing 14 and is located in the central region of the housing 14. The supporting capacitor assembly 3 has multiple module mounting portions distributed circumferentially thereon, and multiple power modules 4 are respectively disposed in their corresponding module mounting portions. Viewed from the center of the housing 14 towards the housing 14, the supporting capacitor assembly 3 is located on the inner side, the multiple power modules 4 are located on the outer side of the supporting capacitor assembly 3, and the housing 14 is located on the outer side of the multiple power modules 4; therefore, the supporting capacitor assembly 3, the multiple power modules 4, and the housing 14 are radially distributed sequentially.

[0029] A portion of the multiple power modules 4 constitutes a first three-phase power conversion unit 41, and another portion of the multiple power modules 4 constitutes a second three-phase power conversion unit 42. The first three-phase power conversion unit 41 has three AC terminals, and the second three-phase power conversion unit 42 also has three AC terminals. The DC terminals of the two three-phase power conversion units are connected to the DC busbar in the supporting capacitor assembly 3, and their AC terminals are respectively connected to the two sets of three-phase windings of the generator via a six-phase AC connection section.

[0030] The aforementioned component relationships allow the supporting capacitor assembly 3 to be located inside the area enclosed by the multiple power modules 4, which are arranged using the circumferential space between the supporting capacitor assembly 3 and the housing 14. The capacitor body, DC bus, and multiple power modules 4 can all be housed within the cylindrical housing 14, and the two three-phase power conversion units can also be grouped around the supporting capacitor assembly 3, thereby adapting the shape of the controller to the contour of the generator end.

[0031] exist Figure 1 In the illustrated embodiment, the outer casing 14 is cylindrical, and both the first end plate 10 and the second end plate 12 have contours adapted to the ends of the outer casing 14. One axial end of the outer casing 14 is connected to the first end plate 10, and the other axial end is connected to the second end plate 12. The outer casing 14 can be bolted to the first end plate 10 and the second end plate 12 for disassembly during assembly and maintenance. The outer casing 14 also serves to enclose internal components and provides a heat transfer path for components such as the AC magnetic ring 6.

[0032] The supporting capacitor assembly 3 includes a capacitor housing, a capacitor body, and a DC bus. The capacitor housing extends axially along the outer casing 14 and has multiple outer surfaces connected sequentially in a circumferential direction. Multiple module mounting portions are formed on the multiple outer surfaces, and the capacitor body and DC bus are disposed within the capacitor housing. The multiple module mounting portions are located on corresponding outer surfaces. After the power module 4 is mounted on the module mounting portion, its side facing the supporting capacitor assembly 3 is opposite to the module mounting portion, and its side away from the supporting capacitor assembly 3 faces the outer casing 14.

[0033] The capacitor casing can be polygonal. Each outer surface of the polygonal capacitor casing provides a planar mounting area for the power module 4, facilitating the contact between the heat dissipation surface of the power module 4 and the corresponding module mounting portion. Multiple outer surfaces are arranged circumferentially, so that the outer sides of multiple power modules 4 together form a near-cylindrical envelope. Thus, with a fixed cross-sectional dimension of the housing 14, a larger number of power modules 4 can be accommodated within the circumferential area of ​​the housing 14.

[0034] Please see Figure 3 and Figure 4 In one embodiment, the capacitor casing is hexagonal prism-shaped and has six outer surfaces connected sequentially along the circumference. Each of the six outer surfaces forms a module mounting portion, and six power modules 4 are respectively disposed in the six module mounting portions. Each power module 4 corresponds to one phase branch, and three of the six power modules 4 constitute a first three-phase power conversion unit 41, while the other three constitute a second three-phase power conversion unit 42.

[0035] The three AC terminals of the first three-phase power conversion unit 41 correspond to the first set of three-phase AC terminals U1, V1, and W1, respectively. The three AC terminals of the second three-phase power conversion unit 42 correspond to the second set of three-phase AC terminals U2, V2, and W2, respectively. The first set of three-phase AC terminals is connected to the first set of three-phase windings of the generator, and the second set of three-phase AC terminals is connected to the second set of three-phase windings of the generator. The AC terminals of the two three-phase power conversion units are separate from each other, while the DC terminals are both connected to the DC busbar to share the capacitor body in the supporting capacitor assembly 3.

[0036] In the illustrated embodiment, each power module 4 may include a half-bridge unit, with one half-bridge unit corresponding to one phase branch. Three power modules 4 form a group of three-phase power conversion units. The power modules 4 may also adopt a package form that integrates multiple power switches internally, as long as the multiple power modules 4 form a first three-phase power conversion unit 41 and a second three-phase power conversion unit 42 in electrical connection, and the multiple power modules 4 are still arranged circumferentially along the supporting capacitor assembly 3.

[0037] Power module 4 can be packaged in a DCM (Digital Compressor) manner, and the power switch can be an IGBT or other suitable power conversion device. The withstand voltage and rated current of power module 4 can be selected based on the DC bus voltage, generator phase current, and output power. In one embodiment, the withstand voltage of power module 4 is 1200V to 1700V, and the rated current is 400A to 1000A. These parameters are used to illustrate a selection range for power module 4 and do not limit power modules 4 to using the same parameters.

[0038] The capacitor body is housed within the capacitor casing and connected between the DC positive and DC negative terminals. The capacitor body may include a single capacitor unit or multiple interconnected capacitor units. The number, capacitance, and connection relationship of the multiple capacitor units can be selected based on the DC bus voltage and allowable voltage fluctuations.

[0039] When power module 4 switches, it generates a pulsating current on the DC side. The capacitor body is located inside the area enclosed by multiple power modules 4 and is connected to the DC terminal of each power module 4 via a DC bus. Therefore, the conductive path between the capacitor body and each power module 4 is relatively short. The capacitor body can supply power to the power module 4 when it needs pulsating current and absorb the corresponding current when the power module 4 feeds current back to the DC side, thereby reducing the fluctuation of the DC bus voltage.

[0040] The DC busbar includes a positive conductive layer, a negative conductive layer, and an insulating layer. The insulating layer is sandwiched between the positive and negative conductive layers, maintaining electrical insulation between them. The positive and negative conductive layers extend along similar paths and are positioned close to each other. The positive conductive layer is electrically connected to the positive terminal of the capacitor body, and the negative conductive layer is electrically connected to the negative terminal of the capacitor body.

[0041] The positive conductive layer has a positive input terminal and multiple positive output terminals, while the negative conductive layer has a negative input terminal and multiple negative output terminals. Each positive output terminal and one negative output terminal form a set of DC output terminals, and multiple sets of DC output terminals correspond one-to-one with multiple power modules 4. The positive output terminal in each set of DC output terminals is electrically connected to the positive DC terminal of the corresponding power module 4, and the negative output terminal is electrically connected to the negative DC terminal of the corresponding power module 4.

[0042] The positive DC terminal of power module 4 can be its P terminal, and the negative DC terminal can be its N terminal. The positive output terminal and the P terminal, and the negative output terminal and the N terminal, can be connected by bolts or other detachable connectors suitable for transmitting high current. Multiple sets of DC output terminals are arranged circumferentially along the capacitor housing, so that each set of DC output terminals is close to the corresponding power module 4, reducing the extension length of the DC busbar outside the capacitor housing.

[0043] The positive and negative conductive layers are close to each other and separated by an insulating layer, which reduces the loop area formed by the DC positive and DC negative currents. When the power module 4 performs rapid switching, the smaller loop area helps reduce parasitic inductance in the DC connection path and reduces voltage spikes when the power module 4 is turned off. In one embodiment, the parasitic inductance of the DC bus can be controlled to within 5nH. This value is related to the shape, spacing, and length of the conductive layers and the connection position of the power module 4, and is not a limitation that must be achieved in all embodiments.

[0044] The supporting capacitor assembly 3 also includes a liquid inlet, a liquid outlet, and multiple cooling channels. Each cooling channel corresponds one-to-one with a module mounting section. Each cooling channel is located on the side of the corresponding module mounting section opposite to the power module 4 and extends along the corresponding module mounting section. The power module 4 has a heat dissipation surface facing the corresponding module mounting section, and the heat dissipation surface is in contact with the corresponding module mounting section.

[0045] Coolant enters the supporting capacitor assembly 3 through the inlet, flows through multiple cooling channels, and exits through the outlet. Each cooling channel is located inside the corresponding module mounting section and forms a heat transfer relationship with the corresponding power module 4. The specific connection order between the multiple cooling channels is not limited.

[0046] The heat generated by power module 4 during operation is transferred from its heat dissipation surface to the module mounting section, and then carried away by the coolant flowing through the cooling channels. The cooling channels correspond one-to-one with the module mounting sections, ensuring that the heat dissipation areas of the six power modules 4 are distributed circumferentially along the capacitor housing. The supporting capacitor assembly 3 thus accommodates both the capacitor body and the DC busbar, and provides mounting positions and cooling paths for multiple power modules 4.

[0047] In some embodiments, the cooling channel is provided with multiple fins distributed within the coolant flow area. As the coolant flows through the gaps between the fins, it contacts the channel wall and the fin surfaces. In other embodiments, the cooling channel forms a tortuous extension path along the module mounting portion, allowing the coolant to travel a longer path within the heat dissipation area of ​​the corresponding power module 4. The finned or tortuous flow channels can be selected based on the heat dissipation surface size of the power module 4 and the wall thickness of the capacitor housing.

[0048] The power module 4 can be directly or indirectly liquid cooled. When using direct liquid cooling, the heat dissipation surface of the power module 4 is in contact with the wall forming the cooling channel, and the heat generated by the power module 4 is transferred to the coolant through this wall. When using indirect liquid cooling, the heat dissipation surface of the power module 4 first contacts the module mounting part or the heat-conducting component, and then the module mounting part or the heat-conducting component transfers the heat to the cooling channel.

[0049] The capacitor housing has multiple first support columns at one end along the axial direction of the outer casing 14, and multiple second support columns at the other end along the axial direction of the outer casing 14. The multiple first support columns are spaced apart circumferentially around the capacitor housing and are respectively connected to the first end plate 10. The multiple second support columns are spaced apart circumferentially around the capacitor housing and are respectively connected to the second end plate 12. Each power module 4 is located between the multiple first support columns and the multiple second support columns.

[0050] The first and second support columns can be integrally formed with the capacitor housing or fixed to the capacitor housing as independent components. The first support column and the first end plate 10, and the second support column and the second end plate 12, can be connected by bolts. The support columns limit the axial spacing between the first end plate 10, the second end plate 12, and the supporting capacitor assembly 3, and transfer the axial load on the two end plates to the capacitor housing. The power module 4 is located between the two sets of support columns, preventing the support columns from occupying the circumferential mounting area where the power module 4 is located.

[0051] The DC connection is located on the side where the first end plate 10 is located. Figure 1 In the illustrated embodiment, the DC connection portion includes a DC connector 1, which is mounted on the first end plate 10. The DC connector 1 has a positive terminal and a negative terminal for connecting to an external DC bus. The DC connector 1 leads out a positive conductor and a negative conductor, respectively.

[0052] The six-phase generator controller also includes a DC filter 2. The DC filter 2 is located at the end of the supporting capacitor assembly 3 facing the first end plate 10, and between the DC connector 1 and the DC busbar. The DC filter 2 has a positive input terminal, a negative input terminal, a positive output terminal, and a negative output terminal. The positive input terminal of the DC filter 2 is electrically connected to the positive terminal of the DC connector 1, and the negative input terminal is electrically connected to the negative terminal of the DC connector 1. The positive output terminal of the DC filter 2 is electrically connected to the positive input terminal of the DC busbar, and the negative output terminal is electrically connected to the negative input terminal of the DC busbar.

[0053] The positive and negative input terminals of the DC filter 2 can be connected to the positive and negative terminals of the DC connector 1 respectively via bent copper busbars. One end of the bent copper busbar is located at the first end plate 10, and the other end extends toward the supporting capacitor assembly 3 and connects to the DC filter 2. When the DC connector 1 and the DC filter 2 are offset radially or axially, the bent copper busbar can conform to this positional relationship and reduce the use of flexible wires in high-current paths.

[0054] The DC filter 2 includes at least one inductor unit and at least two capacitor units. In one embodiment, a first capacitor unit, an inductor unit, and a second capacitor unit are sequentially arranged along the conductive path from the DC connector 1 to the DC busbar. The first capacitor unit is located on the side of the inductor unit closer to the DC connector 1, and the second capacitor unit is located on the side of the inductor unit closer to the DC busbar. In another embodiment, the DC filter 2 includes two stages of inductor-capacitor filter units connected in sequence. The DC filter 2 is used to reduce high-frequency current and high-frequency voltage disturbances propagating along the DC line when the power module 4 performs switching operations.

[0055] The DC-side connection path can be summarized as follows: DC connector 1 connects to DC filter 2, DC filter 2 connects to DC busbar, DC busbar connects to multiple power modules 4 through multiple sets of DC output terminals, and the capacitor body is connected between the positive and negative conductive layers of the DC busbar. DC connector 1, DC filter 2, and DC busbar are centrally arranged along the direction from the first end plate 10 to the supporting capacitor assembly 3, which can reduce the crossing of the main DC power path inside the housing 14.

[0056] Please see Figure 1 , Figure 2 and Figure 6 The six-phase AC connection section is located on one side of the second end plate 12. The six-phase AC connection section includes six single-core AC connectors 7, which are spaced apart circumferentially along the second end plate 12. The six single-core AC connectors 7 correspond to the first group of three-phase AC terminals U1, V1 and W1 and the second group of three-phase AC terminals U2, V2 and W2, respectively.

[0057] The six-phase generator controller also includes six transfer copper busbars 11, multiple current sensors 5, and at least one AC magnetic ring 6. One end of each transfer copper busbar 11 is electrically connected to an AC terminal of either the first three-phase power conversion unit 41 or the second three-phase power conversion unit 42, and the other end is electrically connected to a single-core AC connector 7. The six transfer copper busbars 11 correspond one-to-one with the six phase branches.

[0058] The adapter copper busbar 11 can be in the form of a sheet or a bent sheet, and extends from the AC terminal of the power module 4 toward the second end plate 12. The AC terminal of the power module 4 and the adapter copper busbar 11, and the adapter copper busbar 11 and the single-core AC connector 7 can be connected by bolts. The adapter copper busbar 11 can also be supported by an insulator located between the adapter copper busbar 11 and the second end plate 12 or other metal carriers, so as to keep the adapter copper busbar 11 electrically insulated from adjacent metal parts.

[0059] Multiple current sensors 5 are respectively disposed on corresponding transition copper busbars 11. The detection part of the current sensor 5 is opposite to the transition copper busbar 11. When a phase current flows through the transition copper busbar 11, the current sensor 5 outputs a sampling signal corresponding to the phase current. The sampling signal is transmitted to the main control board 9 via a signal line. In one embodiment, a current sensor 5 is disposed on each of the six transition copper busbars 11, so that the phase current of the six phase branches can be detected respectively.

[0060] At least one AC magnetic ring 6 is disposed on the side of the second end plate 12 facing the supporting capacitor assembly 3 and adjacent to the housing 14. Six phase conductors connected to six single-core AC connectors 7 pass through the AC magnetic ring 6. The six phase conductors may be formed by the conductor portion between the adapter copper busbar 11 and the single-core AC connector 7, or may include cable segments connected to the single-core AC connector 7.

[0061] In some embodiments, six phase conductors share a common AC magnetic ring 6. The AC magnetic ring 6 is arranged around the six phase conductors to form an impedance to the common-mode current on the six-phase AC side. The AC magnetic ring 6 may be made of amorphous material, nanocrystalline material, or ferrite material, and its relative permeability may be selected in the range of 1000 to 80000.

[0062] The AC magnetic ring 6 is located adjacent to the second end plate 12 and the housing 14. The heat generated by the AC magnetic ring 6 during operation can be transferred through its mounting portion to the second end plate 12 or the housing 14, and then dissipated outwards from the second end plate 12 and the housing 14. The AC magnetic ring 6, six adapter copper busbars 11, and six single-core AC connectors 7 are concentrated on one side of the second end plate 12, placing the six-phase AC main power path in the area close to the generator end.

[0063] The single-core AC connector 7 can be a power connector with dustproof and waterproof capabilities to connect the six phase wires separately. The six single-core AC connectors 7 can be evenly distributed along the circumference of the second end plate 12, or they can be distributed non-evenly to avoid mounting holes, cooling interfaces or other components on the second end plate 12. In another embodiment, the six-phase AC connection can also use cable leads such as gland heads, so that the six phase conductors pass through the second end plate 12 and connect to the generator windings.

[0064] Please see Figure 1 and Figure 5The six-phase generator controller also includes a main control board 9, multiple drive boards 8, and a shielding cover 13. The multiple drive boards 8 are respectively located on the side of the corresponding power module 4 away from the supporting capacitor assembly 3, and are electrically connected to the main control board 9 and the corresponding power module 4. The drive boards 8 are located adjacent to the control terminals of the power modules 4 and can be connected to the power modules 4 by welding, crimping, plugging, or snap-fitting.

[0065] The driver board 8 receives the pulse width modulation signal sent by the main control board 9 and controls the power switch in the power module 4 to turn on or off according to the signal. The driver board 8 can also obtain the status signal of the power module 4 and send a fault signal to the main control board 9. The driver board 8 may have short circuit detection, drive power supply overvoltage detection, drive power supply undervoltage detection, power device temperature detection, and DC bus voltage sampling. The above detection functions can be selected according to the interface of the power module 4 and the operating requirements of the controller.

[0066] The main control board 9 is located at the end of the supporting capacitor assembly 3 facing the second end plate 12. The main control board 9 has a phase current sampling interface, a DC bus voltage sampling interface, a resolver interface, a drive signal interface, and a communication interface. The sampling signal from the current sensor 5 is transmitted to the phase current sampling interface, the DC bus voltage signal is transmitted to the DC bus voltage sampling interface, and the rotor position and speed signals of the generator are transmitted to the resolver interface via the resolver connector 15.

[0067] The main control board 9 generates pulse width modulation (PWM) signals corresponding to the multiple power modules 4 based on the acquired phase current signal, DC bus voltage signal, and rotor position signal, and sends the PWM signals to the multiple drive boards 8. The multiple drive boards 8 then control their respective power modules 4. The main control board 9 also receives status signals returned by the multiple drive boards 8 to process the operating status of the two three-phase power conversion units.

[0068] A shielding cover 13 is installed on the side of the main control board 9 opposite to the supporting capacitor assembly 3. The shielding cover 13 may be made of a metallic material, and its outline is adapted to the area where the main control board 9 is located. A gap is maintained between the shielding cover 13 and the main control board 9 to avoid obstructing electronic components on the main control board 9. The shielding cover 13 is used to reduce the high-frequency electromagnetic interference generated by the power module 4 and the AC magnetic ring 6 from entering the area where the main control board 9 is located.

[0069] The resolver connector 15, low-voltage connector 16, and Ethernet connector 17 are all located on the first end plate 10. The resolver connector 15 is used to connect the generator's resolver sensor. The low-voltage connector 16 is used to connect an external low-voltage power supply and low-voltage signal lines. The Ethernet connector 17 is used to connect an external communication line. The main control board 9 can also connect to a CAN communication line or other communication lines via the low-voltage connector 16.

[0070] A wiring channel is provided on the side of the supporting capacitor assembly 3, extending from the end where the main control board 9 is located toward the first end plate 10. The resolver connector 15, the low-voltage connector 16, and the Ethernet connector 17 are respectively connected to the main control board 9 through signal lines provided in the wiring channel. The signal lines of the driver board 8 and the current sensor 5 can also extend to the main control board 9 along the wiring channel or in the area adjacent to the wiring channel.

[0071] The wiring trough can be formed by a groove on the outer side of the capacitor housing or by a slotted component fixed to the outside of the capacitor housing. The wiring trough extends axially, allowing the main control board 9 located on one side of the second end plate 12 to connect with multiple connectors located on the first end plate 10. After the signal lines are placed in the wiring trough, they are kept apart from the DC busbar, the adapter copper busbar 11, and the main power terminal of the power module 4, reducing the crossing of signal lines and main power conductors in the internal space.

[0072] Please see Figure 2 In power generation mode, the first set of three-phase windings of the generator produces the first set of three-phase AC power, and the second set of three-phase windings produces the second set of three-phase AC power. The first set of three-phase AC power corresponds to U1, V1, and W1, and the second set of three-phase AC power corresponds to U2, V2, and W2. The six phase lines are respectively connected to six single-core AC connectors 7, and pass through AC magnetic rings 6 via phase conductors, and then connect to the AC terminals of the first three-phase power conversion unit 41 and the second three-phase power conversion unit 42 via six adapter copper busbars 11.

[0073] Current sensor 5 detects the phase current in the corresponding phase branch and transmits the sampling signal to the main control board 9. The main control board 9 also obtains the DC bus voltage and generator rotor position signals, and sends pulse width modulation signals to multiple drive boards 8 accordingly. The multiple drive boards 8 control the power switches in the corresponding power modules 4, so that the first three-phase power conversion unit 41 and the second three-phase power conversion unit 42 convert the two sets of three-phase AC power into DC power.

[0074] The converted DC power enters the DC busbar through the positive and negative DC terminals of multiple power modules 4. The DC busbar connects the DC sides of the multiple power modules 4, and the capacitors support the DC busbar. The DC power is then transmitted through the DC filter 2 to the DC connector 1, and output from the DC connector 1 to the external DC busbar.

[0075] In embodiments that allow bidirectional power conversion, external DC power can also enter through DC connector 1, be transmitted to DC busbar via DC filter 2, and be distributed to multiple power modules 4 by multiple DC output terminals. The main control board 9 and multiple drive boards 8 control the first three-phase power conversion unit 41 and the second three-phase power conversion unit 42 to convert DC power into two sets of three-phase AC power, which is then transmitted to the two sets of three-phase windings of the generator via six adapter copper busbars 11, AC magnetic rings 6, and six single-core AC connectors 7.

[0076] The first three-phase power conversion unit 41 and the second three-phase power conversion unit 42 are connected to different three-phase windings, and the two sets of AC terminals are separated from each other. The two three-phase power conversion units can operate simultaneously and share the DC bus and capacitor body. The main control board 9 can send control signals to the drive boards 8 corresponding to the two sets of three-phase power conversion units respectively to obtain the operating status of the two sets of three-phase branches.

[0077] During controller operation, the heat generated by the multiple power modules 4 is transferred to the corresponding module mounting section through their respective heat dissipation surfaces. Coolant enters the supporting capacitor assembly 3 through the inlet, flows through multiple cooling channels and carries away the heat generated by the multiple power modules 4, and then flows out through the outlet. Since the multiple cooling channels are distributed circumferentially along the capacitor housing, each power module 4 has a corresponding cooling area.

[0078] In one implementation, with power module 4 using 1700 V and 800 A specifications, and a coolant flow rate of 10 L / min, the controller's output power can reach 700 kW, and the power chip junction temperature is approximately 160 ℃. Increasing the coolant flow rate can further increase the output power. The above data is related to power module 4, coolant inlet temperature, flow rate, switching frequency, and load conditions, and is only used to illustrate one operating state.

[0079] During the assembly of the six-phase generator controller, the capacitor body and DC busbar can be installed into the capacitor housing first, and multiple cooling channels can be formed inside the multiple module mounting parts to obtain the supporting capacitor assembly 3. Subsequently, multiple power modules 4 are installed in the multiple module mounting parts respectively, so that the heat dissipation surface of each power module 4 is in contact with the corresponding module mounting part, and the positive DC terminal and negative DC terminal of each power module 4 are connected to the corresponding set of DC output terminals respectively.

[0080] Multiple drive boards 8 are respectively installed on the side of the corresponding power module 4 facing away from the supporting capacitor assembly 3. Six adapter copper busbars 11 are respectively connected to the AC terminals of the six power modules 4, and current sensors 5 are installed on the corresponding adapter copper busbars 11. A DC filter 2 is installed on the end of the supporting capacitor assembly 3 facing the first end plate 10, and a main control board 9 is installed on the end of the supporting capacitor assembly 3 facing the second end plate 12. A shielding cover 13 is placed on the outside of the main control board 9.

[0081] The first end plate 10 is connected to multiple first support posts, and the second end plate 12 is connected to multiple second support posts. A DC connector 1, a resolver connector 15, a low-voltage connector 16, and an Ethernet connector 17 are mounted on the first end plate 10. Six single-core AC connectors 7 are mounted on the second end plate 12, and an AC magnetic ring 6 is positioned on the side of the second end plate 12 facing the supporting capacitor assembly 3. After all power and signal connections are completed, the housing 14 is fitted over the outside of the multiple power modules 4, and both axial ends of the housing 14 are connected to the first end plate 10 and the second end plate 12, respectively.

[0082] After assembly, the DC connection, resolver connector 15, low-voltage connector 16, and Ethernet connector 17 are concentrated on one side of the first end plate 10, while the six-phase AC connection and AC magnetic ring 6 are concentrated on one side of the second end plate 12. The supporting capacitor assembly 3 is located in the middle, and multiple power modules 4 are distributed circumferentially along the supporting capacitor assembly 3. This arrangement ensures that the DC main power path, the six-phase AC main power path, the signal lines, and the coolant flow path are located in their respective areas.

[0083] This invention also provides a generator assembly. The generator assembly includes a generator and a six-phase generator controller as described in any of the above embodiments. The generator includes an end cover, a first set of three-phase windings, and a second set of three-phase windings. The second end plate 12 is provided with a plurality of mounting holes, and a plurality of fasteners pass through the plurality of mounting holes and are connected to the end cover of the generator, so that the six-phase generator controller is mounted on the end of the generator.

[0084] The six-phase AC connection includes three first-phase terminals and three second-phase terminals. The three first-phase terminals are electrically connected to the three phase terminals of the first set of three-phase windings, and the three second-phase terminals are electrically connected to the three phase terminals of the second set of three-phase windings. In an embodiment using six single-core AC connectors 7, three single-core AC connectors 7 constitute three first-phase terminals, and the other three single-core AC connectors 7 constitute three second-phase terminals.

[0085] After the second end plate 12 is connected to the generator end cover, six single-core AC connectors 7 are positioned adjacent to the phase ends of the two sets of three-phase windings. The generator windings and the six-phase generator controller can be connected via shorter phase conductors. The first end plate 10 is located on the side away from the generator, from which DC connector 1 and multiple low-voltage connectors can be connected to external cables.

[0086] In other embodiments, the housing 14 may be a cylindrical structure with a polygonal or other annular profile, and the capacitor housing may also be a polygonal prism shape other than a hexagonal prism. The number of module mounting parts can be set according to the number of power modules 4. As long as the supporting capacitor assembly 3 is located inside the housing 14, multiple module mounting parts are distributed along the circumference of the supporting capacitor assembly 3, and multiple power modules 4 are located between the supporting capacitor assembly 3 and the housing 14, forming two three-phase power conversion units in terms of electrical connection, it is sufficient.

[0087] The number and circumferential position of the first and second support columns can be selected based on the dimensions of the first end plate 10, the second end plate 12, and the capacitor housing. The form of the DC connector 1 and the single-core AC connector 7 can also be selected based on the connection form of the external cable end. The connection between the housing 14 and the two end plates, the support columns and the two end plates, and the power module 4 and the DC busbar can be made by bolts, or other connection methods that can form a corresponding fixed or conductive relationship can be used.

[0088] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. All modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A six-phase generator controller, characterized in that, It includes a first end plate, a second end plate, a housing, a supporting capacitor assembly, a DC connection section, a six-phase AC connection section, and multiple power modules; The outer casing is cylindrical, and the first end plate and the second end plate are respectively connected to the two axial ends of the outer casing; the supporting capacitor assembly is located inside the outer casing and is provided with multiple module mounting parts distributed circumferentially, and the multiple power modules are respectively disposed in the multiple module mounting parts and located between the supporting capacitor assembly and the outer casing; A portion of the multiple power modules constitutes a first three-phase power conversion unit, and another portion constitutes a second three-phase power conversion unit; The supporting capacitor assembly includes a capacitor body and a DC busbar electrically connected to the capacitor body. The DC busbar is electrically connected to the DC connection part and the DC terminals of the multiple power modules, respectively. The six-phase AC connection part is electrically connected to the AC terminals of the first three-phase power conversion unit and the second three-phase power conversion unit.

2. The six-phase generator controller according to claim 1, characterized in that, The outer shell is cylindrical; The supporting capacitor assembly also includes a capacitor housing extending axially along the outer casing. The capacitor housing is polygonal and has a plurality of outer surfaces connected sequentially along the circumference of the capacitor housing. Multiple module mounting portions are respectively formed on multiple external surfaces, and the capacitor body and the DC bus are disposed inside the capacitor housing.

3. The six-phase generator controller according to claim 2, characterized in that, The capacitor casing is hexagonal prism-shaped and has six outer surfaces; There are six module mounting portions and six power modules. The six module mounting portions are formed on the six outer surfaces, and the six power modules are respectively disposed on the six module mounting portions. Three of the six power modules constitute the first three-phase power conversion unit, and the other three constitute the second three-phase power conversion unit.

4. The six-phase generator controller according to claim 2, characterized in that, The supporting capacitor assembly is provided with a liquid inlet, a liquid outlet, and multiple cooling channels; Each of the multiple cooling channels corresponds one-to-one with a multiple of the module mounting portions. Each cooling channel is located on the side of the corresponding module mounting portion away from the power module and extends along the corresponding module mounting portion. Multiple cooling channels are connected between the liquid inlet and the liquid outlet, and the power module has a heat dissipation surface facing the corresponding module mounting part, the heat dissipation surface being in contact with the corresponding module mounting part.

5. The six-phase generator controller according to claim 1, characterized in that, The DC busbar includes a positive conductive layer, a negative conductive layer, and an insulating layer, wherein the insulating layer is sandwiched between the positive conductive layer and the negative conductive layer; The positive electrode conductive layer has a positive electrode input terminal and multiple positive electrode output terminals, and the negative electrode conductive layer has a negative electrode input terminal and multiple negative electrode output terminals; Each of the positive output terminals and one of the negative output terminals form a set of DC output terminals, and multiple sets of DC output terminals correspond one-to-one with multiple power modules; the positive output terminal and the negative output terminal of each set of DC output terminals are electrically connected to the positive DC terminal and the negative DC terminal of the corresponding power module, respectively.

6. The six-phase generator controller according to claim 2, characterized in that, The capacitor housing is provided with a plurality of first support columns at one end along the axial direction of the outer shell, and a plurality of second support columns at the other end along the axial direction of the outer shell; Multiple first support columns are spaced apart along the circumference of the capacitor housing and are respectively connected to the first end plate; Multiple second support columns are spaced apart along the circumference of the capacitor housing and are respectively connected to the second end plate; Each of the power modules is located between a plurality of first support columns and a plurality of second support columns.

7. The six-phase generator controller according to claim 5, characterized in that, The DC connection part includes a DC connector mounted on the first end plate, and the six-phase generator controller also includes a DC filter; The DC filter is disposed at the end of the supporting capacitor assembly facing the first end plate, and is located between the DC connector and the DC busbar; The positive and negative input terminals of the DC filter are electrically connected to the positive and negative terminals of the DC connector via bent copper busbars, respectively. The positive and negative output terminals of the DC filter are electrically connected to the positive and negative input terminals of the DC busbar, respectively. The DC filter includes at least one inductor unit and at least two capacitor units disposed along the conductive path from the DC connector to the DC bus.

8. The six-phase generator controller according to claim 1, characterized in that, The six-phase AC connection section includes six single-core AC connectors, which are spaced apart circumferentially along the second end plate. The six-phase generator controller also includes six copper busbars, multiple current sensors, and at least one AC magnetic ring; One end of each of the aforementioned adapter copper busbars is electrically connected to an AC terminal of the first three-phase power conversion unit or the second three-phase power conversion unit, and the other end is electrically connected to a single-core AC connector. Multiple current sensors are respectively disposed on the corresponding adapter copper busbars; Six phase conductors connected to the six single-core AC connectors pass through the at least one AC magnetic ring, which is located on the side of the second end plate facing the supporting capacitor assembly and is disposed adjacent to the housing.

9. The six-phase generator controller according to claim 1, characterized in that, It also includes a main control board, multiple driver boards, a shielding cover, a resolver connector, a low-voltage connector, and an Ethernet connector; Multiple drive boards are respectively disposed on the side of the corresponding power module away from the supporting capacitor assembly, and are electrically connected to the main control board and the corresponding power module respectively; The main control board is located at one end of the supporting capacitor assembly facing the second end plate, and the shielding cover is located on the side of the main control board away from the supporting capacitor assembly; The resolver connector, the low-voltage connector, and the Ethernet connector are all disposed on the first end plate; The side of the supporting capacitor assembly is provided with a wiring groove extending from the end where the main control board is located toward the first end plate. The resolver connector, the low-voltage connector and the Ethernet connector are respectively connected to the main control board through signal lines provided in the wiring groove.

10. A generator assembly, characterized in that, Includes a generator and a six-phase generator controller as described in any one of claims 1 to 9; The generator includes an end cover, a first set of three-phase windings, and a second set of three-phase windings; The second end plate is provided with multiple mounting holes, and multiple fasteners pass through the multiple mounting holes and are connected to the end cap; The six-phase AC connection section includes three first-phase terminals and three second-phase terminals. The three first-phase terminals are electrically connected to the three phase ends of the first group of three-phase windings, and the three second-phase terminals are electrically connected to the three phase ends of the second group of three-phase windings.

Images