Motor controller, motor assembly, and vehicle

Abstract

The embodiment of the application relates to the technical field of vehicles, and discloses a motor controller, a motor assembly and a vehicle. The motor controller comprises a shell, an inverter module, a liquid inlet pipeline and a liquid outlet pipeline. The shell is provided with a cavity, and a first mounting channel and a second mounting channel in communication with the cavity. The inverter module is arranged in the cavity and is provided with a first cooling flow channel. The liquid inlet pipeline is arranged in the first mounting channel, the outlet of the liquid inlet pipeline is in communication with the inlet of the first cooling flow channel, and the liquid inlet pipeline is suitable for introducing cooling liquid into the first cooling flow channel. The liquid outlet pipeline is arranged in the second mounting channel, the inlet of the liquid outlet pipeline is in communication with the outlet of the first cooling flow channel, and the liquid outlet pipeline is suitable for discharging the cooling liquid in the first cooling flow channel to the outside of the shell. The technical scheme of the application can solve the problem that the structure of the motor controller is relatively complex.

Description

Technical Field

[0001] This invention relates to the field of vehicle technology, specifically to a motor controller, a motor assembly, and a vehicle. Background Technology

[0002] The motor controller is an important component for controlling the operation of the motor. In order to ensure the function of the motor controller, cooling channels are usually laid on the motor controller to cool it down.

[0003] The prior art provides a motor controller, which includes a power module and a heat dissipation structure for cooling the power module. The heat dissipation structure includes a housing, a heat dissipation substrate, and several heat dissipation fins. The housing has an inlet and an outlet, and the bottom of the housing has an inlet main channel and an outlet main channel respectively communicating with the inlet and outlet. The heat dissipation substrate is disposed within the housing and forms a sealed chamber with the bottom of the housing. One end of the sealed chamber is connected to the inlet main channel, and the other end is connected to the outlet main channel. Several heat dissipation fins are disposed on the side of the heat dissipation substrate facing the sealed chamber, dividing the sealed chamber into multiple parallel branch channels. Adjacent branch channels do not interfere with each other. Turbulence structures are provided within the branch channels to enhance local liquid flow and increase the heat dissipation area for liquid-solid convection heat transfer. The power module is disposed on the upper surface of the heat dissipation substrate to achieve cooling of the power module by the heat dissipation structure.

[0004] While this solution can dissipate heat from the motor controller through a heat dissipation mechanism, it results in a more complex structure for the motor controller. Summary of the Invention

[0005] In view of the shortcomings of the prior art, the purpose of this application is to provide a motor controller, a motor assembly and a vehicle, which aims to solve the problem of the relatively complex structure of the motor controller.

[0006] In a first aspect, embodiments of this application provide a motor controller, including a housing, an inverter module, an inlet pipe, and an outlet pipe. The housing has a cavity and a first mounting channel and a second mounting channel communicating with the cavity. The inverter module is disposed within the cavity and has a first cooling channel. The inlet pipe passes through the first mounting channel, and its outlet is connected to the inlet of the first cooling channel, the inlet pipe being adapted to introduce coolant into the first cooling channel. The outlet pipe passes through the second mounting channel, and its inlet is connected to the outlet of the first cooling channel, the outlet pipe being adapted to discharge the coolant in the first cooling channel to the outside of the housing.

[0007] According to the above technical means, the inlet pipe can receive coolant and pass the coolant into the first cooling channel. The coolant in the first cooling channel can be discharged to the outside of the casing through the outlet pipe. In this way, coolant can be continuously passed into the first cooling channel. When the coolant flows through the first cooling channel, it can absorb the heat generated by the inverter module during operation, thereby cooling the inverter module.

[0008] In the above process, since the inlet pipe is installed in the first installation channel and the outlet pipe is installed in the second installation channel, the coolant can flow into and out of the housing through the inlet and outlet pipes without contacting the housing. Thus, there is no need to set up a channel for coolant flow on the housing, which simplifies the structure of the housing and avoids corrosion of the housing by the coolant. This facilitates the processing of the housing and extends its service life.

[0009] In some embodiments, the motor controller further includes a first seal disposed between the inner wall surface of the first mounting channel and the liquid inlet pipe, adapted to seal the gap between the inner wall surface of the first mounting channel and the liquid inlet pipe. And / or, the motor controller further includes a second seal disposed between the inner wall surface of the second mounting channel and the liquid outlet pipe, adapted to seal the gap between the inner wall surface of the second mounting channel and the liquid outlet pipe.

[0010] According to the above technical means, the gap between the inner wall of the first mounting channel and the liquid inlet pipe can be sealed by the first sealing element, and the gap between the inner wall of the second mounting channel and the liquid outlet pipe can be sealed by the second sealing element, so as to ensure the normal function of the inverter module and other components in the housing, and thus ensure the normal use of the motor controller.

[0011] In some embodiments, the motor controller further includes a first seal. A first mounting groove is provided on the outer peripheral surface of the inlet pipe, extending circumferentially around a first mounting channel. The first seal is fitted onto the inlet pipe and is at least partially located within the first mounting groove. And / or, the motor controller further includes a second seal. A second mounting groove is provided on the outer peripheral surface of the outlet pipe, extending circumferentially around a second mounting channel. The second seal is fitted onto the outlet pipe and is at least partially located within the second mounting groove.

[0012] According to the above-mentioned technical means, by placing at least a portion of the first sealing element within the first mounting groove, the first sealing element can be limited by the first mounting groove, restricting its axial movement along the inlet pipe. This allows the first sealing element to be more stably positioned between the inner wall of the first mounting channel and the inlet pipe, ensuring its sealing effect. Similarly, by placing at least a portion of the second sealing element within the second mounting groove, the second sealing element can be limited by the second mounting groove, restricting its axial movement along the outlet pipe. This allows the second sealing element to be more stably positioned between the inner wall of the second mounting channel and the outlet pipe, ensuring its sealing effect.

[0013] In some embodiments, the motor controller further includes a power module disposed outside the housing and connected to one side of the housing. The power module has a second cooling channel, and the inlet of the liquid inlet pipe is connected to the outlet of the second cooling channel. The liquid inlet pipe is adapted to receive coolant flowing out of the second cooling channel.

[0014] Based on the above technical means, compared with connecting the inlet pipe separately to the coolant supply device, the length and number of pipes required for the motor controller can be reduced, thereby simplifying the structure of the motor controller and facilitating its processing.

[0015] In some embodiments, the motor controller further includes a third seal disposed between the liquid inlet pipe and the power module, and surrounding the inlet of the liquid inlet pipe and the outlet of the second cooling channel, adapted to seal the gap between the liquid inlet pipe and the power module. And / or, the motor controller further includes an adapter and a fourth seal, the power module and the housing forming a mounting cavity, the mounting cavity and the outlet of the second cooling channel being arranged in a direction perpendicular to the arrangement direction of the power module and the housing. The adapter is disposed within the mounting cavity and is electrically connected to both the power module and the inverter module. The fourth seal is disposed between the housing and the power module and surrounds the mounting cavity.

[0016] Based on the aforementioned technical means, a third seal can be used to seal the gap between the inlet pipe and the power module, thereby preventing coolant leakage from this gap and preventing coolant from flowing into the first cooling channel through the inlet pipe, thus ensuring the cooling effect of the coolant on the inverter module. By providing a fourth seal, the gap between the power module and the housing can be sealed, thereby sealing the mounting cavity. This further prevents coolant, water, and other liquids from flowing into the mounting cavity, thereby further improving the stability of the motor controller and ensuring its normal function.

[0017] In some embodiments, the motor controller further includes a drain pipe and a fifth seal, the drain pipe extending at least partially into the outlet pipe. The fifth seal is disposed between the inner circumferential surfaces of the drain pipe and the outlet pipe, and is adapted to seal the gap between the inner circumferential surfaces of the drain pipe and the outlet pipe.

[0018] According to the above-mentioned technical means, the connection between the drain pipe and the outlet pipe enables the coolant discharged from the outlet pipe to be transferred to a suitable location. This reduces the processing difficulty of the motor controller and facilitates its installation. Simultaneously, the fifth seal seals the gap between the inner circumferential surfaces of the drain pipe and the outlet pipe, thereby preventing coolant leakage from this gap and ensuring normal coolant transfer.

[0019] In some embodiments, the liquid outlet pipe includes a first pipe section and a second pipe section, the first pipe section communicating between a first cooling channel and the second pipe section, and the inner diameter of the first pipe section being smaller than the inner diameter of the second pipe section. The liquid outlet pipe passes through the second pipe section, and the inner diameter of the liquid outlet pipe is greater than or equal to the inner diameter of the first pipe section. And / or, the outer circumferential surface of the drain pipe is provided with a limiting protrusion, which at least partially overlaps with and contacts the liquid outlet pipe along the axial direction of the second mounting channel.

[0020] According to the aforementioned technical means, the coolant will not be obstructed at the inlet end of the drain pipe, thus allowing the coolant to flow more smoothly into the drain pipe for easy discharge. Furthermore, during the installation of the drain pipe, the installation position can be positioned using a limiting protrusion, facilitating the installation process.

[0021] In some embodiments, the inverter module includes a base, a control board, and a sixth seal. The base has a groove, and the control board is located at the opening of the groove and connected to the base. The control board seals the opening of the groove to form a first cooling channel with the base. An inlet pipe and an outlet pipe are both connected to the base. The sixth seal is located between the control board and the base, and surrounds the opening of the groove to seal the gap between the control board and the base.

[0022] According to the above-mentioned technical means, the coolant can directly contact one side surface of the control board forming the first cooling channel, thereby directly absorbing the heat generated by the control board during operation, thus improving the cooling effect of the coolant on the control board. At the same time, the sixth seal can seal the gap between the control board and the base, preventing coolant from flowing into the cavity, ensuring the normal function of the control board and other components, and ensuring the normal use of the motor controller.

[0023] In some embodiments, the inlet pipe and the base are integrally formed. And / or, the outlet pipe and the base are integrally formed.

[0024] Based on the above technical means, the overall structural strength of the inlet pipe, outlet pipe and base can be improved, ensuring the normal flow of coolant, and the sealing effect between the base and the inlet and outlet pipes can be improved.

[0025] In some embodiments, the housing is made of magnesium alloy.

[0026] Based on the aforementioned technical means, compared to materials such as aluminum alloy and cast iron, magnesium alloy has a lower density, resulting in a lighter casing. This facilitates the processing and installation of the casing, improves the lightweight nature of the motor controller, and ensures sufficient strength to guarantee its normal function.

[0027] Secondly, embodiments of this application provide a motor assembly including the aforementioned motor controller.

[0028] Thirdly, embodiments of this application provide a vehicle including the aforementioned motor assembly. Attached Figure Description

[0029] To more clearly illustrate the technical solutions in the embodiments of this application or the background art, the accompanying drawings used in the embodiments of this application will be described below.

[0030] Figure 1 This is a schematic diagram of the structure of a vehicle disclosed in an embodiment of this application; Figure 2 This is a schematic diagram of the structure of a motor assembly disclosed in an embodiment of this application; Figure 3 This is a schematic diagram of the structure of a cover and an inverter module disclosed in an embodiment of this application; Figure 4 This is an exploded view of a motor controller disclosed in an embodiment of this application; Figure 5 This is a schematic diagram of the structure of an inverter module disclosed in an embodiment of this application; Figure 6 This is a schematic diagram of another inverter module disclosed in an embodiment of this application; Figure 7 This is a schematic diagram of the structure of a base, an inlet pipe, and an outlet pipe disclosed in an embodiment of this application; Figure 8 This is a cross-sectional schematic diagram of an inlet pipe and a housing disclosed in an embodiment of this application; Figure 9 This is a cross-sectional schematic diagram of an outlet pipe, a drain pipe, and a shell disclosed in an embodiment of this application; Figure 10 This is a cross-sectional schematic diagram of a liquid outlet pipe and a housing disclosed in an embodiment of this application; Figure 11 This is a schematic diagram of the structure of a cover disclosed in an embodiment of this application; Figure 12 This is a schematic diagram of the structure of a cover and a first reinforcing rib disclosed in an embodiment of this application; Figure 13 This is a schematic diagram of the structure of a shell disclosed in an embodiment of this application; Figure 14 This is a schematic diagram of the structure of a first mounting base disclosed in an embodiment of this application; Figure 15 This is a schematic diagram of the structure of a second mounting base disclosed in an embodiment of this application; Figure 16 This is a schematic diagram of the mechanism of a second reinforcing rib and a third reinforcing rib disclosed in an embodiment of this application.

[0031] Explanation of reference numerals in the attached figures: 1000 - Vehicles; 100 - Motor assembly; 10-Motor controller; 1-Outer shell; 11-Cavity; 12-First mounting channel; 13-Second mounting channel; 14-Mounting cavity; 15-Cover; 151-First operating port; 152-Second operating port; 153-First reinforcing rib; 16-Housing shell; 161-First sidewall; 1611-Third mounting surface; 1612-Fourth mounting surface; 1613-Fourth mounting hole; 1614-Second reinforcing rib; 1615-Third reinforcing rib; 162-Second sidewall; 1621-First mounting hole; 1622-Second mounting hole; 1623-First mounting surface; 1624-Second mounting surface; 163 - Third sidewall; 1631 - Third mounting hole; 2-Inverter module; 21-First cooling channel; 22-Control board; 23-Base; 24-Tank; 3-Liquid inlet pipe; 31-First mounting groove; 32-Second chamfer; 4-Liquid outlet pipe; 41-Second mounting groove; 42-First pipe section; 43-Second pipe section; 44-Fourth chamfer; 45-Third mounting groove; 5-Power supply module; 51-Second cooling channel; 61-First seal; 62-Second seal; 63-Third seal; 64-Fourth seal; 65-Fifth seal; 66-Sixth seal; 7-Drain pipe; 71-Limiting protrusion; 81-First mounting base; 811-First chamfer; 82-Second mounting base; 821-Third chamfer; 91-First high-voltage connector; 92-Second high-voltage connector; 93-Branch module; 94-Pressure balance valve; 95-First cover plate; 96-Second cover plate; 97-Low-voltage connector; 98-Three-phase copper busbar connector; 99-Resolver signal connector; 20 - Motor; 30 - Reducer; 200 - Body; 300 - Wheel. Detailed Implementation

[0032] The terms "first," "second," etc., are used for descriptive purposes only and have no sequential or technical meaning, nor should they be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Directional terms used in this application, such as "upper," "lower," "front," "rear," "left," "right," "inner," and "outer," are merely for reference to the orientation shown in the accompanying drawings. The use of directional terms is for better and clearer explanation and understanding of this application, and does not indicate the orientation of the referred device or component in an actual application scenario.

[0033] In the description of the embodiments of this application, unless otherwise expressly specified and limited, the terms "installation" and "connection" should be interpreted broadly. For example, "connection" can be a detachable connection or a non-detachable connection; it can be a direct connection or an indirect connection through an intermediate medium. "Fixed connection" refers to a connection where the relative positional relationship remains unchanged after connection. "Rotary connection" refers to a connection where the two parts can rotate relative to each other after connection. "Sliding connection" refers to a connection where the two parts can slide relative to each other after connection.

[0034] The terms "parallel" and "perpendicular" are relative to the current technological level, not absolute mathematical definitions. Slight deviations are permissible; approximations of parallelism or perpendicularity are acceptable. For example, "A and B are parallel" means that A and B are parallel or approximately parallel, with the angle between them ranging from 0 to 5 degrees. Similarly, "A and B are perpendicular" means that A and B are perpendicular or approximately perpendicular, with the angle between them ranging from 85 to 95 degrees.

[0035] The embodiments of this application are described below with reference to the accompanying drawings.

[0036] like Figure 1 , Figure 2 , Figure 3 As shown, this application provides a vehicle 1000, which includes a motor assembly 100, wheels 300 and a body 200. The wheels 300 are rotatably connected to the body 200, and the motor assembly 100 is connected to the body 200 and is drively connected to the wheels 300 to drive the vehicle 100 to move.

[0037] The motor assembly 100 includes a motor controller 10, a motor 20, and a reducer 30. The motor controller 10 supplies current to the motor 20 so that the motor 20 can work. When the motor 20 is working, the power output can be transmitted to the wheel 300 through the reducer 30 to drive the wheel 300 to rotate.

[0038] Specifically, such as Figures 3 to 8 As shown, the motor controller 10 includes a housing 1, a power supply module 5, and an inverter module 2. The power supply module 5 is located outside the housing 1 and connected to one side of the housing 1.

[0039] The outer casing 1 has a cavity 11, and the inverter module 2 is located inside the cavity 11 and is electrically connected to the power module 5. It is used to receive the DC current transmitted by the power module 5 and convert the DC current into AC current to supply the motor 20 for operation. The outer casing 1 can provide protection for the inverter module 2.

[0040] In some embodiments, such as Figures 3 to 10 As shown, the motor controller 10 also includes an inlet pipe 3 and an outlet pipe 4. The housing 1 is provided with a first mounting channel 12 and a second mounting channel 13 that communicate with the cavity 11.

[0041] The inverter module 2 is provided with a first cooling channel 21.

[0042] The liquid inlet pipe 3 passes through the first installation channel 12, and the outlet of the liquid inlet pipe 3 is connected to the inlet of the first cooling channel 21. The liquid inlet pipe 3 is adapted to introduce coolant into the first cooling channel 21.

[0043] The liquid outlet pipe 4 passes through the second installation channel 13. The inlet of the liquid outlet pipe 4 is connected to the outlet of the first cooling channel 21. The liquid outlet pipe 4 is adapted to discharge the coolant in the first cooling channel 21 to the outside of the outer casing 1.

[0044] With the above configuration, the inlet pipe 3 can receive coolant and pass it into the first cooling channel 21. The coolant in the first cooling channel 21 can be discharged to the outside of the outer casing 1 through the outlet pipe 4. In this way, coolant can be continuously passed into the first cooling channel 21. When the coolant flows through the first cooling channel, it can absorb the heat generated by the inverter module 2 during operation, thereby cooling the inverter module 2.

[0045] In the above process, since the inlet pipe 3 is installed in the first installation channel 12 and the outlet pipe 4 is installed in the second installation channel 13, the coolant can flow into and out of the housing 1 through the inlet pipe 3 and the outlet pipe 4 without contacting the housing 1. Thus, there is no need to set up a channel for coolant flow on the housing 1, which simplifies the structure of the housing 1 and avoids corrosion of the housing 1 by the coolant. This facilitates the processing of the housing 1 and extends the service life of the housing 1.

[0046] For example, the coolant can be ethylene glycol-based coolant, propylene glycol-based coolant, fluorinated coolant, water, etc.

[0047] In some embodiments, the outer casing 1 is made of magnesium alloy.

[0048] Since the housing 1 does not need to have a channel for coolant flow and does not come into contact with coolant, magnesium alloy can be used to process the housing 1. Compared with materials such as aluminum alloy and cast iron, magnesium alloy has a lower density, and the housing 1 made of magnesium alloy is lighter. This makes it easier to process and install the housing 1, improves the lightweight of the motor controller 10, and ensures that the housing 1 has sufficient strength to ensure the normal function of the housing 1.

[0049] Of course, in some other embodiments, the material of the outer shell 1 can also be aluminum alloy, cast iron, etc.

[0050] In some embodiments, such as Figure 4 , Figure 8 As shown, the motor controller 10 also includes a first seal 61, which is disposed between the inner wall of the first mounting channel 12 and the liquid inlet pipe 3, and is suitable for sealing the gap between the inner wall of the first mounting channel 12 and the liquid inlet pipe 3.

[0051] In this way, the gap between the inner wall of the first mounting channel 12 and the liquid inlet pipe 3 can be sealed by the first sealing element 61, thereby preventing coolant, water and other liquids from entering the interior of the housing 1. This prevents coolant, water and other liquids from coming into contact with the inverter module 2 or other components inside the housing 1, which could lead to short circuits or other faults in the inverter module 2 or other components. This ensures the normal function of the inverter module 2 and other components inside the housing 1, and ensures the normal use of the motor controller 10.

[0052] In some other embodiments, the inlet pipe 3 and the outer casing 1 can also be directly welded together to seal the gap between the inner wall of the first mounting channel 12 and the inlet pipe 3.

[0053] Based on this, in some embodiments, such as Figure 4 As shown, the outer circumferential surface of the liquid inlet pipe 3 is provided with a first mounting groove 31, which extends circumferentially along the first mounting channel 12. The first sealing element 61 is sleeved on the liquid inlet pipe 3 and is at least partially located within the first mounting groove 31.

[0054] For example, the first seal 61 can be a sealing ring, a sealing gasket, a sealant, etc.

[0055] By setting the first mounting groove 31, the first sealing element 61 can be fitted onto the liquid inlet pipe 3 before installation, and at least part of the first sealing element 61 can be located in the first mounting groove 31. Then the liquid inlet pipe 3 can be extended into the first mounting channel 12 to complete the installation of the liquid inlet pipe 3 and the first sealing element 61 at the same time, simplifying the installation process of the motor controller 10.

[0056] Meanwhile, by placing at least a portion of the first sealing element 61 within the first mounting groove 31, the first sealing element 61 can be limited by the first mounting groove 31, restricting the first sealing element 61 from moving axially along the liquid inlet pipe 3. This allows the first sealing element 61 to be more stably positioned between the inner wall of the first mounting channel 12 and the liquid inlet pipe 3, ensuring the sealing effect of the first sealing element 61.

[0057] In addition, by placing at least a portion of the first seal 61 within the first mounting groove 31, the contact area between the first seal 61 and the liquid inlet pipe 3 can be increased, thereby improving the sealing effect of the first seal 61 on the gap between the inner wall of the first mounting channel 12 and the liquid inlet pipe 3.

[0058] In some other embodiments, the first seal 61 may also be directly disposed in the gap between the inner wall of the first mounting channel 12 and the liquid inlet pipe 3.

[0059] In some embodiments, such as Figure 4 , Figure 9 , Figure 10 As shown, the motor controller 10 also includes a second seal 62, which is disposed between the inner wall of the second mounting channel 13 and the liquid outlet pipe 4, and is suitable for sealing the gap between the inner wall of the second mounting channel 13 and the liquid outlet pipe 4.

[0060] In this way, the gap between the inner wall of the second mounting channel 13 and the liquid outlet pipe 4 can be sealed by the second seal 62, thereby preventing coolant, water and other liquids from entering the housing 1. This prevents coolant, water and other liquids from contacting the inverter module 2 or other components inside the housing 1, which could lead to short circuits or other faults in the inverter module 2 or other components. This ensures the normal function of the inverter module 2 and other components inside the housing 1, and ensures the normal use of the motor controller 10.

[0061] In some other embodiments, the liquid outlet pipe 4 and the outer casing 1 can also be welded together directly to seal the gap between the inner wall of the second mounting channel 13 and the liquid outlet pipe 4.

[0062] Based on this, in some embodiments, such as Figure 4 , Figure 9 , Figure 10As shown, the outer circumferential surface of the liquid outlet pipe 4 is provided with a second mounting groove 41, which extends circumferentially along the second mounting channel 13. The second sealing element 62 includes a sealing sleeve disposed on the liquid outlet pipe 4, and is at least partially located within the second mounting groove 41.

[0063] By setting the second mounting groove 41, the second sealing element 62 can be fitted onto the liquid outlet pipe 4 in advance before installing the liquid outlet pipe 4, and at least part of the second sealing element 62 is located in the second mounting groove 41. Then the liquid outlet pipe 4 can be extended into the second mounting channel 13 to complete the installation of the liquid outlet pipe 4 and the second sealing element 62 at the same time, simplifying the installation process of the motor controller 10.

[0064] Meanwhile, by placing at least a portion of the second seal 62 within the second mounting groove 41, the second seal 62 can be limited by the second mounting groove 41, restricting the axial movement of the second seal 62 along the liquid outlet pipe 4. This allows the second seal 62 to be more stably positioned between the inner wall of the second mounting channel 13 and the liquid outlet pipe 4, ensuring the sealing effect of the second seal 62.

[0065] In addition, by placing at least a portion of the second seal 62 within the second mounting groove 41, the contact area between the second seal 62 and the liquid outlet pipe 4 can be increased, thereby improving the sealing effect of the second seal 62 on the gap between the inner wall of the second mounting channel 13 and the liquid outlet pipe 4.

[0066] In some other embodiments, the second seal 62 may also include sealant, gasket, etc., and the second seal 62 may also be directly disposed between the inner wall of the second installation channel 13 and the liquid outlet pipe 4.

[0067] In some embodiments, such as Figure 4 , Figure 8 As shown, the power module 5 is provided with a second cooling channel 51, and the inlet of the liquid inlet pipe 3 is connected to the outlet of the second cooling channel 51. The liquid inlet pipe 3 is adapted to receive the coolant flowing out from the second cooling channel 51.

[0068] By having the inlet pipe 3 receive the coolant flowing out of the second cooling channel 51, the second cooling channel 51 and the first cooling channel 21 can be connected in series. After the coolant cools the power module 5, it can flow into the first cooling channel 21 to cool the inverter module 2, thereby achieving the cooling of the inverter module 2.

[0069] Compared to connecting the inlet pipe 3 separately to the coolant supply device, the length and number of pipes required for the motor controller 10 can be reduced, thereby simplifying the structure of the motor controller 10 and facilitating its manufacturing.

[0070] At the same time, it can make full use of the coolant and improve the heat absorption effect of the coolant.

[0071] Of course, in some other embodiments, the liquid inlet pipe 3 may also be directly connected to the liquid supply device that supplies coolant.

[0072] In some embodiments, such as Figure 8 As shown, the motor controller 10 also includes a third seal 63, which is disposed between the liquid inlet pipe 3 and the power module 5 and surrounds the inlet of the liquid inlet pipe 3 and the outlet of the second cooling channel 51, and is suitable for sealing the gap between the liquid inlet pipe 3 and the power module 5.

[0073] In this way, the gap between the liquid inlet pipe 3 and the power module 5 can be sealed by the third seal 63, thereby preventing the coolant from leaking from the gap between the liquid inlet pipe 3 and the power module 5, so as to prevent the coolant from flowing into the first cooling channel 21 through the liquid inlet pipe 3, and ensuring the cooling effect of the coolant on the inverter module 2.

[0074] For example, the third seal 63 can be a sealing ring, a sealing gasket, a sealant, etc.

[0075] In some embodiments, the third seal 63 may also include a sealing sleeve that passes through the liquid inlet pipe 3 and the second coolant flow channel to seal the gap between the liquid inlet pipe 3 and the power module 5.

[0076] In some embodiments, such as Figure 4 , Figure 8 As shown, the motor controller 10 also includes an adapter and a fourth seal 64. The power module 5 and the housing 1 form a mounting cavity 14. The mounting cavity 14 and the outlet of the second cooling channel 51 are arranged in a direction perpendicular to the arrangement direction of the power module 5 and the housing 1.

[0077] For example, the adapter can be an adapter cable, an adapter copper busbar, etc.

[0078] The adapter is located inside the mounting cavity 14 and is electrically connected to both the power module 5 and the inverter module 2. The fourth seal 64 is located between the housing 1 and the power module 5 and surrounds the mounting cavity 14.

[0079] With the above configuration, the power module 5 and the inverter module 2 can be electrically connected through the adapter, thereby enabling the power module 5 to transmit current to the inverter module 2. The adapter is located in the mounting cavity 14, which facilitates the electrical connection between the adapter and the power module 5 and the inverter module 2.

[0080] By arranging the outlets of the mounting cavity 14 and the second cooling channel 51 in a direction perpendicular to the arrangement direction of the power module 5 and the housing 1, the liquid inlet pipe 3 can be located outside the mounting cavity 14 to prevent the coolant from flowing directly into the mounting cavity 14 through the gap between the liquid inlet pipe 3 and the power module 5, thus avoiding the coolant from affecting the adapter. This can improve the stability of the motor controller 10 and ensure the normal function of the motor controller 10.

[0081] Meanwhile, by setting a fourth sealing element 64, the fourth sealing element 64 can seal the gap between the power module 5 and the housing 1 to seal the mounting cavity 14. This can further prevent coolant, water and other liquids from flowing into the mounting cavity 14, thereby further improving the stability of the motor controller 10 and ensuring the normal function of the motor controller 10.

[0082] For example, the fourth seal 64 can be a sealing ring, a sealing gasket, a sealant, etc.

[0083] In some embodiments, such as Figure 4 , Figure 9 , Figure 10 As shown, the motor controller 10 also includes a drain pipe 7 and a fifth seal 65, with the drain pipe 7 extending at least partially into the outlet pipe 4.

[0084] The fifth sealing element 65 is disposed between the inner circumferential surfaces of the drain pipe 7 and the outlet pipe 4, and is suitable for sealing the gap between the inner circumferential surfaces of the drain pipe 7 and the outlet pipe 4.

[0085] For example, the fifth seal 65 can be a sealing ring, a sealing gasket, a sealant, etc.

[0086] With the above configuration, the drain pipe 7 is connected to the outlet pipe 4, which can transmit the coolant discharged from the outlet pipe 4 to a suitable location (such as a storage tank, a cooling component for cooling the coolant, etc.). This reduces the processing difficulty of the motor controller 10 and facilitates the installation of the motor controller 10.

[0087] Meanwhile, the fifth seal 65 can seal the gap between the inner circumferential surfaces of the drain pipe 7 and the outlet pipe 4, thereby preventing coolant from leaking from the gap between the inner circumferential surfaces of the drain pipe 7 and the outlet pipe 4 and ensuring the normal transmission of coolant.

[0088] In some examples, vehicle 1000 also includes a liquid storage tank and a drain pipe 7 connected to the liquid storage tank.

[0089] In some other embodiments, the liquid outlet pipe 4 may also be directly connected to components such as the liquid storage tank and the cooling components for cooling the coolant, and the liquid drain pipe 7 may also be fitted onto the liquid outlet pipe 4.

[0090] In some embodiments, such as Figure 4 , Figure 9 , Figure 10 As shown, the inner circumferential surface of the liquid outlet pipe 4 is provided with a fifth mounting groove, and the fifth sealing element 65 is at least partially located in the fifth mounting groove.

[0091] By placing at least a portion of the fifth sealing ring within the fifth mounting groove, the fifth sealing element 65 can be limited by the fifth mounting groove, restricting the axial movement of the fifth sealing ring along the liquid outlet pipe 4. This allows the fifth sealing ring to be more stably positioned between the inner circumferential surfaces of the sealing drain pipe 7 and the liquid outlet pipe 4, ensuring the sealing effect of the fifth sealing ring.

[0092] In some embodiments, such as Figure 8 , Figure 9 As shown, the liquid outlet pipe 4 includes a first pipe section 42 and a second pipe section 43. The first pipe section 42 is connected between the first cooling channel 21 and the second pipe section 43, and the inner diameter of the first pipe section 42 is smaller than the inner diameter of the second pipe section 43. The liquid outlet pipe passes through the second pipe section 43, and the inner diameter of the liquid outlet pipe is greater than or equal to the inner diameter of the first pipe section 42.

[0093] With the above configuration, since the inner diameter of the outlet pipe is greater than or equal to the inner diameter of the first pipe section 42, the coolant will not be blocked at the inlet end of the drain pipe 7 during the flow of coolant from the first pipe section 42 to the drain pipe 7. This allows the coolant to flow more smoothly into the drain pipe 7 so as to discharge the coolant.

[0094] Meanwhile, along the axial direction of the outlet pipe 4, the first pipe section 42 and the drain pipe 7 can at least partially overlap, so that the drain pipe 7 can be limited by the first pipe section 42, which facilitates the installation of the drain pipe 7.

[0095] Of course, in some other embodiments, the inner diameters of the first pipe section 42 and the second pipe section 43 can be the same.

[0096] In some embodiments, such as Figure 8 As shown, the outer circumferential surface of the drain pipe 7 is provided with a limiting protrusion 71. Along the axial direction of the second installation channel 13, the limiting protrusion 71 at least partially overlaps with the drain pipe 4 and contacts the drain pipe 4.

[0097] During the installation of the drain pipe 7, the drain pipe 7 can be gradually inserted into the outlet pipe 4 until the limiting protrusion 71 contacts the outlet pipe 4, thus realizing the installation of the drain pipe 7. In this way, the installation position of the drain pipe 7 can be positioned by the limiting protrusion 71, so as to facilitate the installation of the drain pipe 7.

[0098] In some other embodiments, a protrusion may be provided on the inner wall of the outlet pipe 4, and a groove may be provided on the outer wall of the drain pipe 7. The drain pipe 7 is positioned by extending the protrusion into the groove and making the side wall of the groove away from the first pipe section 42 contact the protrusion.

[0099] In some embodiments, such as Figures 4 to 8 As shown, the inverter module 2 includes a base 23, a control board 22, and a sixth sealing element 66. The base 23 has a groove 24, and the control board 22 is located at the opening of the groove 24 and connected to the base 23. The control board 22 seals the opening of the groove 24 to form a first cooling channel 21 with the base 23. The liquid inlet pipe 3 and the liquid outlet pipe 4 are both connected to the base 23.

[0100] The sixth seal 66 is located between the control plate 22 and the base 23 and surrounds the opening of the groove 24 to seal the gap between the control plate 22 and the base 23.

[0101] For example, the sixth seal 66 can be a sealing ring, a sealing gasket, a sealant, etc.

[0102] With the above configuration, since the control board 22 blocks the opening of the tank 24 to form the first cooling channel 21, the coolant can directly contact one side surface of the control board 22 forming the first cooling channel 21 during the process of the coolant flowing through the first cooling channel 21, thereby directly absorbing the heat generated by the control board 22 when it is working, thus improving the cooling effect of the coolant on the control board 22.

[0103] Meanwhile, the sixth seal 66 can seal the gap between the control board 22 and the base 23, thereby preventing coolant from leaking from the gap between the control board 22 and the base 23, preventing coolant from flowing into the cavity 11, ensuring the normal function of the control board 22 and other components, and ensuring the normal use of the motor controller 10.

[0104] In some other embodiments, the first cooling channel 21 can be a channel located inside the base 23, through which the coolant exchanges heat with the control board 22.

[0105] In some embodiments, the inverter module 2 further includes multiple heat dissipation columns, all of which are connected to the control board 22 and extend at least partially into the first cooling channel 21. This improves the cooling effect of the coolant on the control board 22.

[0106] In some embodiments, the inlet pipe and the base are integrally formed.

[0107] This improves the overall structural strength of the inlet pipe and the base, ensuring the normal flow of coolant. Compared to separate inlet pipe and base, when the inlet pipe and base are integrally molded, there is no need to seal the gap between the inlet pipe and the base, thus improving the sealing effect between the base and the inlet pipe.

[0108] Of course, in some other embodiments, the liquid inlet pipe and the base can also be set separately.

[0109] In some embodiments, the liquid outlet pipe and the base are integrally formed.

[0110] This improves the overall structural strength of the outlet pipe and the base, ensuring the normal flow of coolant. Compared to separate outlet pipe and base, when the outlet pipe and base are integrally molded, there is no need to seal the gap between the outlet pipe and the base, thus improving the sealing effect between the base and the outlet pipe.

[0111] Of course, in some other embodiments, the liquid outlet pipe and the base can also be set separately.

[0112] In some embodiments, such as Figure 6 As shown, the inverter module 2 also includes a capacitor connected to the control board 22 and the base 23 on the same side in a direction perpendicular to the arrangement direction of the housing 1 and the power module 5. The capacitor is electrically connected between the power module 5 and the control board 22 to reduce the inductance generated when the motor controller 10 is working, thereby improving the working efficiency of the inverter module 2.

[0113] In some embodiments, such as Figure 2 , Figure 4 as well as Figures 11 to 13 As shown, the outer casing 1 includes a housing 16 with an opening on one side and a cover 15. The cover 15 is disposed at the opening of the housing 16 and forms a cavity 11 with the housing 16. The side wall of the housing 16 away from the cover 15 is a first side wall 161. At least a portion of the first mounting channel 12 and at least a portion of the second mounting channel 13 are disposed on the first side wall 161. The power module 5 is connected to the side of the first side wall 161 away from the cover 15.

[0114] This allows the cover 15 to open the cavity 11, facilitating the installation of the inverter module 2. Furthermore, connecting the power module 5 to the side of the first sidewall 161 away from the cover 15 facilitates the electrical connection between the inverter module 2 and the power module 5.

[0115] In some embodiments, such as Figure 13 , Figure 14As shown, the outer casing 1 also includes a first mounting base 81, which is connected to a first side wall 161. The first side wall 161 has a first opening, and the first mounting base 81 has a first channel. The first opening communicates with the first channel to form a first mounting channel 12.

[0116] In this way, the liquid inlet channel can be supported by the first mounting base 81 to ensure the stability of the liquid inlet channel installed in the first mounting channel 12, and the thickness of the first side wall 161 can be set to be smaller to save the material required for processing the housing 16 and facilitate the processing of the housing 16.

[0117] In some embodiments, such as Figure 5 , Figure 14 As shown, the end of the first channel away from the first opening has a first chamfer 811. The outer peripheral edge of the end where the inlet of the liquid inlet pipe 3 is located has a second chamfer 32.

[0118] This facilitates the insertion of the liquid inlet pipe 3 into the first installation channel 12, making the installation of the liquid inlet pipe 3 easier.

[0119] In some embodiments, such as Figure 13 , Figure 15 As shown, the outer casing 1 also includes a second mounting base 82, which is connected to the first side wall 161. The first side wall 161 has a second opening, and the second mounting base 82 has a second channel. The second opening communicates with the second channel and forms a second mounting channel 13.

[0120] In this way, the liquid outlet channel can be supported by the first mounting base to ensure the stability of the liquid outlet channel installed in the second mounting channel 13, and the thickness of the first side wall 161 can be set to be smaller to save the material required for processing the housing 16 and facilitate the processing of the housing 16.

[0121] In some embodiments, such as Figure 5 , Figure 10 , Figure 15 As shown, the end of the second channel away from the second opening has a third chamfer 821. The outer peripheral edge of the end where the outlet of the liquid outlet pipe 4 is located has a fourth chamfer 44.

[0122] This facilitates the insertion of the liquid outlet pipe 4 into the second installation channel 13, making the installation of the liquid outlet pipe 4 easier.

[0123] In some embodiments, such as Figure 4 , Figure 13 As shown, the housing 16 also includes a second sidewall 162 and a third sidewall 163, which are both connected between the first sidewall 161 and the cover 15 and are arranged opposite to each other.

[0124] The second sidewall 162 is provided with a first mounting hole 1621 and a second mounting hole 1622, and includes a first mounting surface 1623 and a second mounting surface 1624. The third sidewall 163 is provided with a third mounting hole 1631.

[0125] The motor controller 10 also includes a first DC connector, a second DC connector, a first high-voltage connector 91, a second high-voltage connector 92, a branch module 93, and a pressure balancing valve 94.

[0126] The first DC connector is installed in the first mounting hole 1621, the second DC connector is installed in the second mounting hole 1622, the first high-voltage connector 91 and the second high-voltage connector 92 are respectively connected to the first mounting surface 1623 and the second mounting surface 1624, the branch module 93 is located in the cavity 11, and the pressure balancing valve 94 is installed in the third mounting hole 1631.

[0127] The first DC connector and the second DC connector are used to connect to the positive terminal and the negative terminal of the power module 5, respectively, and the first DC connector, the second DC connector, the inverter module 2, the first high-voltage connector 91 and the second high-voltage connector 92 are all connected to the branching module 93.

[0128] Thus, the first DC connector and the second DC connector can transmit the current from the power module 5 to the distribution module 93. After the DC current is transmitted to the distribution module 93, the distribution module 93 can transmit the DC current to the inverter module 2 and can receive the AC current converted by the inverter module 2. The AC current is then distributed to electrical equipment (such as air conditioner compressors, heaters, etc.) through the first high-voltage connector 91 and the second high-voltage connector 92.

[0129] Furthermore, by setting a pressure balancing valve 94, the gas pressure inside the cavity 11 can be adjusted to prevent other pressures inside the cavity 11 from being too high or too low, thus ensuring the normal operation of the motor controller 10.

[0130] In some embodiments, such as Figure 4 , Figure 13 As shown, the cover 15 is provided with a first operating port 151 and a second operating port 152, and the outer shell 1 also includes a first cover plate 95 and a second cover plate 96. The first cover plate 95 and the second cover plate 96 are both located outside the cavity 11 and are respectively sealed to the first operating port 151 and the second operating port 152.

[0131] Thus, during the operation of the motor controller 10, the first cover plate 95 and the second cover plate 96 can seal the first operating port 151 and the second operating port 152, preventing liquids such as water from entering the cavity 11 and ensuring the normal function of the motor controller 10.

[0132] Furthermore, when it is necessary to inspect the motor controller 10, the first cover plate 95 and the second cover plate 96 can be removed to open the first operation port 151 and the second operation port 152. The wiring of the branch module 93 can be inspected through the first operation port 151 and the second operation port 152, which facilitates the inspection and maintenance of the motor controller 10.

[0133] In some embodiments, such as Figure 4 , Figure 13 As shown, the first sidewall 161 is also provided with a third mounting surface 1611, a fourth mounting surface 1612 and a fourth mounting hole 1613, and the housing 1 also includes a low-voltage connector 97, a three-phase copper busbar connector 98 and a resolver signal connector 99.

[0134] Low-voltage connector 97 and three-phase copper bus connector 98 are respectively connected to the third mounting surface 1611 and the fourth mounting surface 1612, and are located within the cavity 11. Low-voltage connector 97 connects between control board 22 and motor 20, and is used to transmit control signals transmitted by control board 22 to motor 20. Three-phase copper bus connector 98 connects between control board 22 and motor 20, and is used to transmit the three-phase current converted by control board 22 to motor 20 to power motor 20.

[0135] The resolver signal connector 99 is installed in the fourth mounting hole 1613 and connected between the motor 20 and the control board 22. It is used to obtain parameters such as the rotor position and speed of the motor 20 and transmit these parameters to the control board 22 so that the control board 22 can control the operation of the motor 20.

[0136] In some embodiments, such as Figure 4 , Figure 12 , Figure 16 As shown, the cover 15 has a first reinforcing rib 153 on the side near the first sidewall 161. The first sidewall 161 has a second reinforcing rib 1614 and a third reinforcing rib 1615 on the side away from the cover 15.

[0137] In this way, the structural strength of the cover 15 can be strengthened by the first reinforcing rib 153, and the structural strength of the first side wall 161 can be strengthened by the second reinforcing rib 1614 and the third reinforcing rib 1615. This can improve the overall structural strength of the outer shell 1 and enhance the protection effect of the outer shell 1 on the inverter module 2, etc.

[0138] It should be understood that the application of this application is not limited to the examples above. Those skilled in the art can make improvements or modifications based on the above description, and all such improvements and modifications should fall within the protection scope of the appended claims. Those skilled in the art can understand that implementing all or part of the processes of the above embodiments and making equivalent changes according to the claims of this application still fall within the scope of this application.

Claims

1. A motor controller, characterized in that, It includes a housing (1), an inverter module (2), an inlet pipe (3), and an outlet pipe (4); the housing (1) is provided with a cavity (11) and a first mounting channel (12) and a second mounting channel (13) communicating with the cavity (11); The inverter module (2) is located inside the cavity (11) and is provided with a first cooling channel (21). The liquid inlet pipe (3) passes through the first installation channel (12), the outlet of the liquid inlet pipe (3) is connected to the inlet of the first cooling channel (21), and the liquid inlet pipe (3) is adapted to introduce coolant into the first cooling channel (21); The liquid outlet pipe (4) passes through the second installation channel (13), the inlet of the liquid outlet pipe (4) is connected to the outlet of the first cooling channel (21), and the liquid outlet pipe (4) is adapted to discharge the coolant in the first cooling channel (21) to the outside of the outer shell (1).

2. The motor controller according to claim 1, characterized in that, It also includes a first sealing element (61), which is disposed between the inner wall surface of the first mounting channel (12) and the liquid inlet pipe (3), and is suitable for sealing the gap between the inner wall surface of the first mounting channel (12) and the liquid inlet pipe (3); And / or, the motor controller (10) further includes a second seal (62) disposed between the inner wall of the second mounting channel (13) and the liquid outlet pipe (4), adapted to seal the gap between the inner wall of the second mounting channel (13) and the liquid outlet pipe (4).

3. The motor controller according to claim 1, characterized in that, The motor controller (10) further includes a first sealing element (61); the outer peripheral surface of the liquid inlet pipe (3) is provided with a first mounting groove (31), the first mounting groove (31) extends circumferentially around the first mounting channel (12); the first sealing element (61) is sleeved on the liquid inlet pipe (3) and is at least partially located in the first mounting groove (31); And / or, the motor controller (10) further includes a second seal (62); the outer peripheral surface of the liquid outlet pipe (4) is provided with a second mounting groove (41), the second mounting groove (41) extends circumferentially around the second mounting channel (13); the second seal (62) is sleeved on the liquid outlet pipe (4) and is at least partially located in the second mounting groove (41).

4. The motor controller according to claim 1, characterized in that, It also includes a power module (5), which is located outside the housing (1) and connected to one side of the housing (1); The power module (5) is provided with a second cooling channel (51), the inlet of the liquid inlet pipe (3) is connected to the outlet of the second cooling channel (51), and the liquid inlet pipe (3) is adapted to receive the coolant flowing out from the second cooling channel (51).

5. The motor controller according to claim 4, characterized in that, The motor controller (10) further includes a third seal (63), which is disposed between the liquid inlet pipe (3) and the power module (5) and surrounds the inlet of the liquid inlet pipe (3) and the outlet of the second cooling channel (51), and is adapted to seal the gap between the liquid inlet pipe (3) and the power module (5). And / or, the motor controller (10) further includes an adapter and a fourth seal (64), the power module (5) and the housing (1) form a mounting cavity (14), the outlets of the mounting cavity (14) and the second cooling channel (51) are arranged in a direction perpendicular to the arrangement direction of the power module (5) and the housing (1); the adapter is disposed in the mounting cavity (14) and is electrically connected to both the power module (5) and the inverter module (2); the fourth seal (64) is disposed between the housing (1) and the power module (5) and surrounds the mounting cavity (14).

6. The motor controller according to claim 1, characterized in that, It also includes a drain pipe (7) and a fifth seal (65), the drain pipe (7) extending at least partially into the outlet pipe (4); The fifth sealing element (65) is disposed between the inner circumferential surfaces of the drain pipe (7) and the outlet pipe (4), and is suitable for sealing the gap between the inner circumferential surfaces of the drain pipe (7) and the outlet pipe (4).

7. The motor controller according to claim 6, characterized in that, The liquid outlet pipe (4) includes a first pipe section (42) and a second pipe section (43). The first pipe section (42) is connected between the first cooling channel (21) and the second pipe section (43). The inner diameter of the first pipe section (42) is smaller than the inner diameter of the second pipe section (43). The liquid outlet pipe passes through the second pipe section (43), and the inner diameter of the liquid outlet pipe is greater than or equal to the inner diameter of the first pipe section (42). And / or, the outer peripheral surface of the drain pipe (7) is provided with a limiting protrusion (71), which overlaps at least partially with the outlet pipe (4) and contacts the outlet pipe (4) along the axial direction of the second installation channel (13).

8. The motor controller according to claim 1, characterized in that, The inverter module (2) includes a base (23), a control board (22), and a sixth sealing element (66); the base (23) is provided with a groove (24), the control board (22) is located at the opening of the groove (24) and connected to the base (23); the control board (22) blocks the opening of the groove (24) to form the first cooling channel (21) with the base (23); the liquid inlet pipe (3) and the liquid outlet pipe (4) are both connected to the base (23). The sixth sealing element (66) is disposed between the control plate (22) and the base (23) and surrounds the opening of the groove (24) to seal the gap between the control plate (22) and the base (23).

9. The motor controller according to claim 8, characterized in that, The inlet pipe (3) is integrally formed with the base (16); and / or, the outlet pipe (4) is integrally formed with the base (16).

10. The motor controller according to claim 1, characterized in that, The outer shell (1) is made of magnesium alloy.

11. A motor assembly, characterized in that, Includes the motor controller (10) as described in any one of claims 1-10.

12. A vehicle, characterized in that, Includes the motor assembly (100) as described in claim 11.

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