A motor controller, electric drive assembly, vehicle

Abstract

The application discloses a motor controller, an electric drive assembly and a vehicle, which can reduce the demand for design space, and is relatively simple to operate and can reduce cost. The motor controller provided by the application comprises a power module and a capacitor, the power module and the capacitor are each provided with at least one pair of first terminals, each pair of the first terminals comprises a positive terminal and a negative terminal; the capacitor and the power module are distributed along a first direction, at least one pair of the first terminals of the capacitor extends out of the capacitor along a second direction, at least one pair of the first terminals of the power module extends out of the power module along the second direction, the first direction and the second direction intersect; the positive terminal of the capacitor and the positive terminal of the power module are connected in abutment, and the negative terminal of the capacitor and the negative terminal of the power module are connected in abutment.

Description

Technical Field

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

[0002] The power module in the motor controller has connecting copper busbars, namely a positive copper busbar 011 and a negative copper busbar 012. A pair of positive copper busbars 011 and negative copper busbars 012 are arranged along the width direction of the connecting copper busbars, as shown below. Figure 12 As shown, Figure 12 This is a structural schematic diagram of a power module 01, which has three pairs of connecting copper busbars.

[0003] Power module 01 needs to be connected to a capacitor. The connection copper busbar for the capacitor can be found in [reference needed]. Figure 12 It is understood that during assembly, laser welding or screw fastening is mostly used to fix the connecting copper busbars of the power module 01 to the connecting copper busbars of the capacitor. The laser welding or screw fastening connection method affects the design of the circuit board and even the housing design of the motor controller. For example, with screw fastening, the circuit board needs to have a notch to avoid the screw, and because the connecting copper busbar is relatively thin, a nut is also needed to ensure a secure fastening effect. For laser welding, welding space needs to be considered, and sufficient tooling fixture space needs to be reserved in advance. All of these connection methods result in large overall design space requirements for the motor controller, inconvenient operation, and higher costs. Summary of the Invention

[0004] The purpose of this application is to provide a motor controller, electric drive assembly, and vehicle that can reduce the design space requirements, and is relatively easy to operate and can reduce costs.

[0005] To solve the above-mentioned technical problems, the motor controller provided in this application includes a power module and a capacitor. Both the power module and the capacitor are provided with at least one pair of first terminals, and each pair of first terminals includes a positive terminal and a negative terminal.

[0006] The capacitor and the power module are distributed along a first direction, at least one pair of first terminals of the capacitor extend out of the capacitor along a second direction, and at least one pair of first terminals of the power module extend out of the power module along the second direction, wherein the first direction and the second direction intersect.

[0007] The positive terminal of the capacitor is connected to the positive terminal of the power module, and the negative terminal of the capacitor is connected to the negative terminal of the power module.

[0008] Optionally, the first terminal includes a first terminal segment and a second terminal segment connected to each other, the first terminal segment extending along the second direction, and the second terminal segment bent relative to the first terminal segment and extending along the first direction;

[0009] The second segment of the positive terminal of the capacitor and the second segment of the positive terminal of the power module are connected abutting each other along the thickness direction, and the second segment of the negative terminal of the capacitor and the second segment of the negative terminal of the power module are connected abutting each other along the thickness direction.

[0010] Optionally, the motor controller includes a housing having a top and a bottom distributed along the first direction, the capacitor being supported at the bottom of the housing and potted to the housing.

[0011] Optionally, the motor controller further includes a cooling component located between the power module and the capacitor in the first direction.

[0012] Optionally, portions of at least one pair of the first terminals of the power module are located between a corresponding pair of the first terminals of the capacitor;

[0013] Alternatively, portions of at least one pair of the first terminals of the capacitor may be located between a corresponding pair of the first terminals of the power module.

[0014] Optionally, at least one of the first terminals of the capacitor is provided with a slot, and the first terminal of the corresponding power module is inserted into the slot of the corresponding capacitor;

[0015] At least one of the first terminals of the power module is provided with a slot, and the first terminal of the corresponding capacitor is inserted into the slot of the corresponding power module.

[0016] Optionally, the first terminal of the capacitor and the corresponding first terminal of the power module are interference-fitted.

[0017] Optionally, the motor controller includes an elastic structure; at least one positive terminal of the capacitor and the corresponding positive terminal of the power module are pressed together by the elastic structure; at least one negative terminal of the capacitor and the corresponding negative terminal of the power module are pressed together by the elastic structure.

[0018] Optionally, at least a portion of a pair of first terminals of the power module is located between a corresponding pair of first terminals of the capacitor, and the motor controller further includes an elastic structure located at least partially between a pair of first terminals of the power module, the elastic structure pressing against the first terminals of the power module;

[0019] Alternatively, portions of at least one pair of the first terminals of the capacitor are located between a corresponding pair of the first terminals of the power module, and the motor controller further includes an elastic structure located at least partially between the pair of the first terminals of the capacitor, the elastic structure pressing against the first terminals of the capacitor.

[0020] Optionally, the elastic structure is a spring sheet; or the elastic structure is an elastic pin.

[0021] Optionally, the cross-sectional size of the elastic pin gradually increases along the extension direction of the pair of first terminals directly pressed by the elastic pin.

[0022] Optionally, the outer surface of at least the portion of the resilient pin used to press against the first terminal is made of an insulating material.

[0023] Optionally, a portion of the elastic pin is located between a pair of first terminals corresponding to the power module, and abuts against the pair of first terminals of the power module;

[0024] A portion of the resilient pin is located between a pair of first terminals of the capacitor and is connected to the pair of first terminals of the capacitor via potting compound.

[0025] Optionally, the motor controller includes an insulating film, with the insulating film between at least one pair of the first terminals.

[0026] Optionally, each pair of the first terminals is disposed opposite to each other along the thickness direction of the first terminal.

[0027] Optionally, the first direction and the second direction are perpendicular.

[0028] This application also provides an electric drive assembly including the motor controller described in any of the above claims.

[0029] This application also provides a vehicle including the above-described electric drive assembly.

[0030] In this application's technical solution, the positive and negative terminals of the motor controller power module can be connected to the corresponding positive and negative terminals of the capacitor, meaning the power module and capacitor terminals are connected by contact. Compared to welding or screw connections mentioned in the background art, this contact connection method reduces space requirements and offers advantages such as simpler and faster assembly, streamlined production lines, and lower costs. Furthermore, the power module and capacitor are distributed along a first direction, while the first terminals of both the power module and the capacitor extend along a second direction, intersecting each other. This arrangement allows for efficient connection of the first terminals of the power module and capacitor during assembly, while also maintaining a compact spatial arrangement.

[0031] The electric drive assembly and vehicle provided in this application have the same technical effects. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the connection between the power module and the capacitor of the motor controller in the first embodiment of this application;

[0033] Figure 2 for Figure 1 Assembly diagram of medium power module and capacitor;

[0034] Figure 3 for Figure 1 A schematic diagram showing the end position of the first terminal in a medium-power module;

[0035] Figure 4 A three-dimensional schematic diagram of the layout of two first terminals that are parallel to each other and connected in series;

[0036] Figure 5 for Figure 4 The front view;

[0037] Figure 6 This is a schematic diagram of the connection between the power module and the capacitor of the motor controller in the second embodiment of this application;

[0038] Figure 7 This is a schematic diagram of the connection between the power module and the capacitor of the motor controller in the fourth embodiment of this application;

[0039] Figure 8 This is a schematic diagram of the connection between the power module and the capacitor of the motor controller in the fourth embodiment of this application;

[0040] Figure 9 for Figure 8 A schematic diagram of the structure of a medium-capacitor;

[0041] Figure 10 This is a schematic diagram of the connection between the power module and the capacitor of the motor controller in the fifth embodiment of this application;

[0042] Figure 11 for Figure 10 Schematic diagram of the medium power module;

[0043] Figure 12 This is a schematic diagram of a power module.

[0044] The annotations in the attached figures are explained as follows:

[0045] 10 - Power module; 10a - Slot;

[0046] 101 - Module positive terminal; 1011 - Module positive terminal first segment; 1012 - Module positive terminal second segment;

[0047] 102 - Negative end of module; 1021 - First segment of negative end of module; 1022 - Second segment of negative end of module;

[0048] 103 - Main body of module;

[0049] 20 - Capacitor; 20a - Slot;

[0050] 201 - Capacitor positive terminal; 2011 - First segment of capacitor positive terminal; 2012 - Second segment of capacitor positive terminal; 20121 - First terminal bifurcation;

[0051] 202 - Capacitor negative terminal; 2021 - First segment of capacitor negative terminal; 2022 - Second segment of capacitor negative terminal; 20221 - Second terminal bifurcation;

[0052] 203 - Capacitor core;

[0053] 30 - Cooling component; 40 - Insulating film;

[0054] 501 - Flexible pin; 502 - Spring clip;

[0055] 60-screw;

[0056] 100 - Terminal 1; 200 - Terminal 2. Detailed Implementation

[0057] To enable those skilled in the art to better understand the present application, the present application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0058] The ordinal numbers used in this article, such as first and second, are used to distinguish different parts with the same name and do not indicate a specific order or primary / secondary relationship.

[0059] Please refer to Figure 1 and Figure 2 , Figure 1 This is a schematic diagram of the connection between the power module and the capacitor of the motor controller in the first embodiment of this application; Figure 2 for Figure 1 Assembly diagram of medium power module and capacitor.

[0060] The motor controller in this embodiment includes a power module 10 and a capacitor 20. The power module 10 and the capacitor 20 are two devices of the motor controller. The power module 10 performs AC-DC conversion, for example, using diode semiconductors, IGBT semiconductors, SiC semiconductors, etc. Each device in the motor controller has at least one pair of first terminals at one end. Each pair of first terminals is a first terminal on the DC side, and each pair of first terminals is a positive terminal and a negative terminal. In this embodiment, the pair of first terminals of the capacitor 20 is defined as capacitor positive terminal 201 and capacitor negative terminal 202, and the pair of first terminals of the power module 10 is defined as module positive terminal 101 and module negative terminal 102. Specifically, the power module 10 includes a module body 103 and module positive terminal 101 and module negative terminal 102 connected to the module body 103. The module positive terminal 101 and module negative terminal 102 extend out of the module body 103 and can extend perpendicularly to one end of the module body 103. Capacitor 20 includes a capacitor body and a capacitor positive terminal 201 and a capacitor negative terminal 202 connected to the capacitor body. The capacitor body includes, for example, a capacitor main body. Figure 1 The multiple capacitor cores 203 shown, the positive terminal 201 and the negative terminal 202 of the capacitor can also extend from one end perpendicular to the capacitor body.

[0061] The motor controller in this embodiment is, for example, an electric drive assembly used in a vehicle. More specific applications could be single-phase half-bridge, three-phase full-bridge, four-phase full-bridge, or six-phase full-bridge modules for motor drivers. Taking a three-phase full-bridge as an example, a three-phase full-bridge includes three half-bridges, each half-bridge comprising an upper half-bridge and a lower half-bridge. The upper and lower half-bridges each include a first chip and a second chip connected in reverse parallel with it. The first chip can be an IGBT (Insulated Gate Bipolar Transistor), and the second chip can be a fast recovery diode. The first chip can be made of SiC material. Each half-bridge, or bridge arm, corresponds to a pair of first terminals. For example, in this embodiment, the power module 10 has a three-phase full-bridge, so three pairs of first terminals are provided on the DC side, and the capacitor 20 is correspondingly provided with three pairs of first terminals. The two positive and negative terminals of the power module 10 are connected to the two positive and negative terminals of the capacitor 20. The capacitor 20 and the power module 10 can also be provided with other terminals. For example, the capacitor 20 can be provided with a second terminal, which can be connected to the DC side. The power module 10 can be provided with a third terminal, which can be connected to the AC side. For example, the power module 10 can be connected to the stator winding of the motor.

[0062] like Figure 3 As shown, Figure 3 for Figure 1 The structural diagram of the end position of the first terminal of the medium power module 10 shows a pair of first terminals, and the other pairs of first terminals are set in the same way.

[0063] In this embodiment, the first terminal (module positive terminal 101, module negative terminal 102, capacitor positive terminal 201 and capacitor negative terminal 202) is a busbar with a plate-like structure, or more specifically, a copper busbar. Figure 3 The diagram illustrates the positive terminal 101 and the negative terminal 102 of the module. The first terminal can be defined as having a width W1, a length L1, and a thickness T1. The direction of the length L1 is also the direction of current flow in the first terminal. The thickness T1 of the first terminal is smaller than the width W1 and the length L1, generally much smaller. The direction of the width W1 of the first terminal is also the width direction of the power module 10. A pair of first terminals of the capacitor 20 can be referenced... Figure 3 Understanding the first terminal of the medium power module 10.

[0064] It is worth noting that in this embodiment, the pair of first terminals of capacitor 20 and the pair of first terminals of power module 10 are arranged opposite each other along the thickness direction of the first terminals. As mentioned above, the first terminal is a plate-like structure, so the first terminal can be defined as having a first terminal surface perpendicular to the thickness direction. Arranging opposite each other along the thickness direction means that the first terminal surface on one side of the positive terminal and the first terminal surface on one side of the negative terminal are arranged opposite each other. For example, the module positive terminal 101 and the module negative terminal 102 can be arranged in parallel, and the capacitor positive terminal 201 and the capacitor negative terminal 202 can be arranged in parallel. Of course, they can also be arranged at a certain angle instead of parallel.

[0065] In this embodiment, when projected along the thickness direction of the first terminals, the projections of the module positive terminal 101 and the module negative terminal 102 coincide in the width direction, as do the projections of the capacitor positive terminal 201 and the capacitor negative terminal 202. This coincidence can mean complete overlap of a pair of first terminals in the width direction, i.e., one edge of the projection of the positive terminal in the width direction aligns with one edge of the projection of the corresponding negative terminal in the width direction, and the other edge of the projection of the positive terminal in the width direction aligns with the other edge of the projection of the corresponding negative terminal in the width direction, meaning the widths of the two first terminals are equal. However, this alignment is not absolute; for example, misalignment within a set error range is allowed. Alternatively, the overlap can also mean that the projection of one of the pair of first terminals falls within the projection range of the other in the width direction, i.e., the width of one first terminal can be greater than the width of the other first terminal.

[0066] In this embodiment, the first terminals of the two positive and two negative terminals of the power module 10 and the capacitor 20 are spaced apart with their surfaces facing each other. Thus, in the width direction of the power module 10 or the capacitor 20, it is no longer necessary to arrange two first terminals simultaneously as in the prior art. Therefore, the width of the first terminal can be set to be wider; for example, the width of the first terminal of the power module 10 can be greater than half the width W2 of the module body 103, or even close to the width W2. In this embodiment, the widths of the capacitor positive terminal 201, the capacitor negative terminal 202, the module positive terminal 101, and the module negative terminal 102 are designed to be wider, which helps to reduce the series parasitic inductance ESL (Equivalent Series Inductance, hereinafter referred to as Ls) in the circuit between the power module 10 and the capacitor 20, thereby reducing the switching losses of the power module 10 and improving efficiency.

[0067] The specific principles behind the technical effects achieved by this arrangement are described in detail below:

[0068] The inventors studied multiple parameters affecting the performance of the electric drive assembly and discovered that the DC-side bus voltage of the electric drive assembly fluctuated significantly. Further research revealed that one of the reasons for this large bus voltage fluctuation was the large surge voltage V. When the electric drive assembly performs high-speed on / off control of the power module, the surge voltage V is applied to the current loop of the power module, resulting in large bus voltage fluctuations, which in turn affects the performance of the electric drive assembly.

[0069] The surge voltage V is directly proportional to the magnitude of the series parasitic inductance Ls introduced at the first terminal in the current loop. The formula for calculating the surge voltage V is:

[0070] (1)

[0071] in, is the rate of change of current in the current loop.

[0072] like Figure 4 and Figure 5 As shown, Figure 4 This is a three-dimensional schematic diagram of the layout of two first terminals that are parallel to each other and connected in series. The two first terminals are terminal 100 and terminal 200. Figure 5 for Figure 4 Front view, Figure 5 for Figure 4 A schematic diagram from the perspective of the length direction of the first terminal. Figure 4 The bold unidirectional arrow indicates the direction of current flow in the current loop.

[0073] Figure 5 and Figure 4Terminal 100 and Terminal 200 can be two parallel and series-connected DC first terminals in a motor driver. For example, Terminal 100 and Terminal 200 can be the positive and negative terminals of the power module 10, or the positive and negative terminals of a capacitor. The first terminal is also a plate-shaped first terminal. The width of Terminal 100 and Terminal 200 is set to W, and the length is set to L. The length L is also the length direction of the circuit loop, that is, the current flows along the length L. The thickness of Terminal 100 and Terminal 200 is t, and the distance between them is d.

[0074] for Figure 3 and Figure 4 The arrangement of the first terminals shown, and the empirical formula for calculating Ls in the current loop for the two first terminals is as follows:

[0075] (2)

[0076] Where L1 and L2 represent the self-inductance of the two first terminals, and M represents the mutual inductance between the two first terminals. k is the coupling coefficient, which reflects the degree of coupling between the two first terminals. When the centers of the two first terminals are not aligned along the width direction ( When ≠1), the value of k (<1) will be affected. ws is the overlap dimension of the two first terminals in the width direction, and the overlap ratio of the first terminals in the width direction. The larger the value (the greater the degree of misalignment of the first terminal centers and the smaller the degree of overlap), the smaller the value of k.

[0077] Based on formula (2), the formula for Ls can also be expressed as:

[0078] (3)

[0079] in, ρ is the magnetic permeability in vacuum.

[0080] Based on formulas (1), (2) and (3), it can be seen that when the length L of the first terminal is smaller, the width W of the first terminal is larger, and the thickness t of the first terminal is larger, Ls is smaller and the surge voltage V is smaller; when ws / W is larger (the overlap ratio of the first terminal is larger), the k value is larger, Ls is smaller and the surge voltage V is smaller.

[0081] In this embodiment, the positive terminal 101 and the negative terminal 102 of the module (which can be respectively compared to...) Figure 4 Terminal 100, Terminal 200), capacitor positive terminal 201 and capacitor negative terminal 202 (which can be compared with...) Figure 4If terminals 100 and 200 are arranged opposite each other along the thickness direction, then theoretically the width W1 of the first terminal only needs to be less than the width W2. In this way, the width W1 of the first terminal can be significantly increased. The positive terminal 101 and the negative terminal 102 of the module, and the positive terminal 201 and the negative terminal 202 of the capacitor can overlap in the width direction, or even completely overlap. That is, the projections of each pair of first terminals along the thickness direction can partially overlap or even completely overlap. Then the overlap ratio mentioned above can reach ws / W=1 or close to 1.

[0082] Combining the above formulas (1), (2), and (3), it can be seen that the first terminal layout in this embodiment can effectively reduce Ls and surge voltage V, thereby improving the stability of the bus voltage and enhancing the performance of the electric drive assembly.

[0083] like Figure 1 As shown, the positive terminal 201 of the capacitor and the positive terminal 101 of the module are connected in an abutting manner, and the negative terminal 202 of the capacitor and the negative terminal 102 of the module are connected in an abutting manner. That is, both the first terminals of the capacitor 20 and the power module 10 have abutting portions for abutting connection with their corresponding first terminals. Specifically, in this embodiment, the positive terminal 201 of the capacitor and the positive terminal 101 of the module are connected in an abutting manner along the thickness direction, and the negative terminal 202 of the capacitor and the negative terminal 102 of the module are connected in an abutting manner along the thickness direction. That is, the surface of the first terminal of the positive terminal 201 of the capacitor abuts against the surface of the first terminal of the positive terminal 101 of the module, and the surface of the first terminal of the negative terminal 202 of the capacitor abuts against the surface of the first terminal of the negative terminal 102 of the module. It can be seen that the surface of the first terminal is the abutting portion. It is worth noting that the width W1 of the first terminal in this embodiment is much larger than the width of the first terminal in the prior art, so that when this abutting connection method is adopted, a larger contact area can be obtained, and the connection can be more reliable while reducing contact resistance. It should be noted that the power module 10 and capacitor 20 are assembled as a whole and do not need to be disassembled. Since the first terminal is arranged along the width direction and the width of the first terminal is relatively narrow, the contact resistance of direct contact is difficult to control. Therefore, the conventional connection method in the background art is to achieve a fixed connection by welding or screw connection. In this embodiment, since the first terminal is distributed along the thickness direction, the width of the first terminal can be set to be wider. Compared with the method of arranging the first terminal along the width direction in the background art, the ESL is reduced while the contact connection between the first terminals can be achieved. Compared with the welding or screw connection mentioned in the background art, the design space requirements are reduced, and it has the advantages of simple and quick assembly, saving production line processes and reducing costs.

[0084] Figure 1In this configuration, at least a portion of a pair of first terminals of the power module 10 is located between a pair of first terminals of the capacitor 20, and the pair of first terminals of the power module 10 can be inserted between the pair of first terminals of the capacitor 20. For example... Figure 2 As shown, the insertion portion of a pair of first terminals of the power module 10 can have a spacing d1, which is the distance between the opposite surfaces of the first terminals of the insertion portion. The insertion portion of a pair of first terminals of the capacitor 20 can have a spacing d2, which is the distance between the adjacent surfaces of the first terminals of the capacitor 20. d1 can be greater than d2. In this way, after the pair of first terminals of the power module 10 are inserted into the pair of first terminals of the capacitor 20, an interference fit can be achieved. Then, the positive terminal 101 of the module and the positive terminal 201 of the capacitor can abut along the thickness direction, and the negative terminal 102 of the module and the negative terminal 202 of the capacitor can also abut along the thickness direction, thereby achieving a reliable connection.

[0085] exist Figure 1 In the illustrated embodiment, the motor controller further includes an elastic structure, specifically an elastic pin 501. This elastic structure can press against the positive terminal 201 of the capacitor and the positive terminal 101 of the module along the thickness direction, and can also press against the negative terminal 202 of the capacitor and the negative terminal 102 of the module along the thickness direction of the first terminal. That is, the elasticity of the elastic structure better ensures reliable contact between the positive and negative terminals, improving the reliability of the connection.

[0086] For example, the elastic pin 501 is located between the positive terminal 101 and the negative terminal 102 of the module. The elastic pin 501 can be pressed to both sides to simultaneously press the positive terminal 101 against the positive terminal 201 of the capacitor and the negative terminal 102 against the negative terminal 202 of the capacitor. That is, the elastic pin 501 is in a compressed state between the positive terminal 101 and the negative terminal 102 of the module to generate the required elastic force.

[0087] The aforementioned pair of first terminals of the power module 10 can be directly interference-fitted with the pair of first terminals of the capacitor 20, with the elastic pin 501 providing further protection. It is understood that the pair of first terminals of the power module 10 and the pair of first terminals of the capacitor 20 are not limited to a direct interference fit; for example, d1 can be no greater than d2. After the positive terminal 101 and negative terminal 102 of the module are inserted into the pair of first terminals of the capacitor 20, the elastic pin 501 can tighten and press to achieve contact.

[0088] For example, along the extension direction of the pair of first terminals directly pressed by the resilient pin 501, the cross-sectional size of the resilient pin 501 gradually increases. Figure 1The pair of first terminals directly pressed by the elastic pin 501 are the module positive terminal 101 and the module negative terminal 102. The portions of these two first terminals and the elastic pin 501 are along... Figure 1 As shown, the first direction Z extends downwards, and the cross-sectional dimensions of the elastic pin 501 gradually increase downwards. This creates a gradually decreasing gap between the elastic pin 501 and the positive and negative terminals 201 and 202 of the capacitor, providing a guiding effect for the insertion of the positive and negative terminals 101 and 102 of the module.

[0089] Understandable. Figure 1 The power module 10 shown is inserted between a pair of first terminals of the capacitor 20. The reverse arrangement is also possible; the pair of first terminals of the capacitor 20 can also be inserted between the pair of first terminals of the power module 10. That is, at least a portion of the pair of first terminals of the capacitor 20 is located between the pair of first terminals of the power module 10, and at least a portion of the elastic structure is located between the pair of first terminals of the capacitor 20. The specific principle and... Figure 1 The embodiments shown are the same and will not be described again.

[0090] Furthermore, in this embodiment, the capacitor 20 and the power module 10 are distributed along the first direction Z, which is also... Figure 1 The vertical direction from a viewing angle. A pair of first terminals extend out of the end of the corresponding capacitor 20 or the end of the power module 10 along the second direction Y. Specifically, the positive terminal 101 and the negative terminal 102 of the module extend out of the power module 10 along the second direction Y, and the positive terminal 201 and the negative terminal 202 of the capacitor extend out of the capacitor 20 along the second direction Y. The first direction Z and the second direction Y intersect, and in this embodiment, the first direction Z and the second direction Y are perpendicular.

[0091] At this time, each first terminal includes a first terminal segment and a second terminal segment connected to each other. The first terminal segment can extend beyond the end of the capacitor 20 or the power module 10. The first terminal segment extends along the second direction Y, and the second terminal segment is bent relative to the first terminal segment and extends along the first direction Z. Figure 2 As shown, four terminal segments and terminal segments can be defined here, namely, module positive terminal segment 1011, module positive terminal segment 1012, module negative terminal segment 1021, module negative terminal segment 1022, capacitor positive terminal segment 2011, capacitor positive terminal segment 2012, capacitor negative terminal segment 2021, and capacitor negative terminal segment 2022.

[0092] The capacitor positive terminal second segment 2012 and the module positive terminal second segment 1012 are connected by abutting along the thickness direction, and the capacitor negative terminal second segment 2022 and the module negative terminal second segment 1022 are connected by abutting along the thickness direction.

[0093] In other words, based on Figure 1 In this embodiment, the first terminal is bent to accommodate the arrangement of the capacitor 20 and the power module 10. This allows the first segment of the terminal to extend along either the capacitor 20 or the power module 10, specifically extending away from either end of the capacitor 20 or the power module 10 in the direction of the second direction Y. The extension direction of the second segment of the bent terminal can be the same as the distribution direction of the capacitor 20 and the power module 10 (i.e., the first direction Z). In other words, if the distribution direction of the capacitor 20 and the power module 10 (the first direction Z) intersects with the extension direction of the first terminal (the second direction Y), it facilitates the connection of the first terminal. Figure 2 As shown, when assembling the power module 10 and the capacitor 20, they can be brought close to each other along the first direction Z to achieve the abutment connection of the first terminals of the power module 10 and the capacitor 20. For example, the power module 10 can be moved downwards to assemble and connect. The assembly is simple and convenient. At the same time, compared with the power module 10 and the capacitor 20 being distributed along the second direction Y, this layout along the first direction Z makes the structure of the motor driver more compact.

[0094] In this embodiment, the first direction Z is... Figure 1 From a vertical perspective, the first direction Z is also the height direction of capacitor 20 and the thickness direction of power module 10.

[0095] Correspondingly, such as Figure 1 As shown, capacitor 20 includes multiple capacitor cores 203. One end of each capacitor core 203 is connected to the positive terminal 201 of the capacitor, specifically to the first segment 2011 of the positive terminal of the capacitor. The other end of each capacitor core 203 is connected to the negative terminal 202 of the capacitor, specifically to the first segment 2021 of the negative terminal of the capacitor.

[0096] The motor driver also includes a housing (not shown in the figure), into which the aforementioned capacitor 20 is housed. After the capacitor 20 is placed inside the housing, it can be glued together; that is, a liquid glue is filled between the capacitor 20 and the housing. Once the glue solidifies, the capacitor 20 is reliably fixed to the housing. The housing has a top and a bottom distributed along the first direction Z, and the capacitor 20 can be supported at the bottom of the housing. At this time, the power module 10 is moved along the first direction Z closer to the capacitor 20, i.e., in… Figure 1The viewpoint moves from top to bottom to electrically connect the power module 10 and the capacitor 20. It can be seen that, based on this, it is more convenient to assemble the power module 10 and the capacitor 20 along the first direction Z for the capacitor 20 fixed in the housing.

[0097] Let's look again. Figure 2 When the capacitor 20 and the power module 10 are distributed along the first direction Z, the elastic pin 501 can be pre-installed on the capacitor 20. As mentioned earlier, the capacitor 20 can be fixed to the housing with potting compound, resulting in relatively good fixation and sealing performance between the capacitor 20 and the housing. In this case, the capacitor 20 is located at the bottom of the housing, making it more convenient to assemble the power module 10 and the capacitor 20 vertically from top to bottom. Moreover, the top and bottom of the capacitor 20 are relatively large surfaces, and this vertical arrangement also makes it easier to ensure the reliability of the potting connection. If the power module 10 and the capacitor 20 are distributed along the second direction Y, sufficient space needs to be reserved in the second direction Y for assembly operations, which would waste housing space, and the capacitor 20 would not be convenient to potting connect with the housing. In this embodiment, the power module 10 and the capacitor 20 are distributed along the first direction Z, resulting in a compact layout, saving space, and allowing the capacitor 20 to be potted connected to the housing with relatively reliable connection.

[0098] Furthermore, the elastic pin 501 can be pre-placed between the positive terminal 201 and the negative terminal 202 of the capacitor. During potting, the adhesive is simultaneously poured between the elastic pin 501 and the capacitor 20, thus fixing the elastic pin 501 and the two first terminals of the capacitor 20 relative to each other. Of course, a gap needs to be left between the elastic pin 501 and the first terminals of the capacitor 20 for the insertion of the first terminals of the power module 10. Therefore, if a pair of first terminals of the capacitor 20 are inserted between a pair of first terminals of the power module 10, the elastic pin 501 can also be fixed between the two first terminals of the power module 10.

[0099] The motor controller in this embodiment also includes an insulating film 40 for insulating and isolating the positive and negative terminals. Furthermore, the elastic pin 501 in this embodiment is made of insulating material, thus providing insulation for the two first terminals it presses against. Figure 1In this configuration, the flexible pin 501 directly abuts against the second segment 1012 of the positive terminal and the second segment 1022 of the negative terminal. In this case, the insulating film 40 does not need to cover the second segment 1012 and the second segment 1022 of the positive terminal; it only needs to cover the first segment 1011 of the positive terminal and the first segment 1021 of the negative terminal. Alternatively, if the flexible pin 501 is not made of insulating material, two insulating layers can be provided: one covering the entire surface of the first terminal of the positive terminal 101, and the other covering the entire surface of the first terminal of the negative terminal 102. Furthermore, the flexible pin 501 is not limited to being entirely made of insulating material; at least the outer surface of the portion used to press against the first terminal needs to be insulating. For example, the flexible pin 501 could include a pin body and an insulating layer covering the outer periphery of the pin body.

[0100] Figure 1 The diagram also illustrates a cooling component 30, which can be a water-cooled structure including a water-cooled housing. The water-cooled housing has cooling channels for water flow. The cooling component 30 is located at the bottom of the power module 10 and can cool the power module 10. The power module 10 and the cooling component 30 can be fixedly connected by screws 60. After the capacitor 20 and the power module 10 are assembled, the cooling component 30 is located between the power module 10 and the capacitor 20 in the first direction Z. The cooling component 30 can be positioned above the capacitor 20 first, and then the power module 10 can be moved downwards to connect with the cooling component 30 and the capacitor 20.

[0101] When the cooling component 30 and the power module 10 are assembled, they are fixed relative to the housing. If the power module 10 and the capacitor 20 are distributed along the second direction Y, and the power module 10 and the cooling component 30 are not suitable for movement after assembly due to sealing requirements, the capacitor 20 can move along the second direction Y and connect with the power module 10, which would also cause the capacitor 20 to be unable to be potted and connected to the housing.

[0102] Please refer to Figure 6 , Figure 6 This is a schematic diagram of the connection between the power module and the capacitor of the motor controller in the second embodiment of this application.

[0103] This embodiment has a structure that is basically the same as the first embodiment, except that in the second embodiment, the elastic structure is specifically a spring piece 502. The function of the spring piece 502 is the same as that of the elastic pin 501 described above; both rely on elastic force to press against the positive terminal 101 of the module and the positive terminal 201 of the capacitor, and to press against the negative terminal 102 of the module and the negative terminal 202 of the capacitor. Specifically... Figure 6 In the middle, there are the second segment 1012 of the positive terminal of the pressure module, the second segment 2012 of the positive terminal of the capacitor, the second segment 1022 of the negative terminal of the pressure module, and the second segment 2022 of the negative terminal of the capacitor.

[0104] The spring clip 502 can be pre-installed between the positive terminal 101 and the negative terminal 102 of the module. During assembly, the positive terminal 101 and the negative terminal 102 of the module can be pressed along the thickness direction of the first terminal to further compress the spring clip 502. After assembly, it can be released. The spring clip 502 can be pre-assembled between the positive terminal 101 and the negative terminal 102 of the module and can be fixedly connected to this pair of first terminals of the power module 10 to ensure the contact effect of the spring clip 502 with the first terminal. The size and elasticity of the spring clip 502 can be preset according to requirements.

[0105] Similar to the first embodiment, in the second embodiment, at least a portion of a pair of first terminals of capacitor 20 may be inserted into a pair of first terminals of power module 10, in which case the spring 502 directly presses against the pair of first terminals of capacitor 20.

[0106] The motor controller in this embodiment may also include an insulating film 40, which is used for insulation between the positive and negative terminals. Figure 6 The device can be provided with two insulating films 40. One insulating film 40 covers the surface of the first terminal on one side of the positive terminal 101 of the module, and the other insulating film 40 covers the surface of the first terminal on one side of the negative terminal 102 of the module. The two insulating films 40 are arranged opposite to each other. When the spring piece 502 is provided, the spring piece 502 is located between the two insulating films 40 and abuts against the insulating film 40.

[0107] In the first and second embodiments, the capacitor 20 and the power module 10 are connected by a plug-in connection, but this is not limited to the insertion of a pair of first terminals of the capacitor 20 into a pair of first terminals of the power module 10, or the insertion of a pair of first terminals of the power module 10 into a pair of first terminals of the capacitor 20. Other plug-in methods are also possible, such as... Figure 7 As shown, Figure 7 This is a schematic diagram of the connection between the power module and the capacitor of the motor controller in the fourth embodiment of this application.

[0108] Figure 7 In this embodiment, the first terminal of the capacitor 20 and the first terminal of the power module 10 are staggered. The first terminal is defined to have a first side and a second side along its thickness direction. Therefore, the first terminal of the capacitor 20 abuts against the first side surface of the power module, or the first side surface of the capacitor 20 abuts against the second side surface of the power module. Comparatively, the insertion methods in the first and second embodiments make the abutment more reliable, and the elastic structure facilitates pre-assembly.

[0109] Besides the aforementioned connection methods, the connection between capacitor 20 and power module 10 is not limited to the two methods described above; other forms are also possible, such as... Figure 8 and Figure 9 As shown, Figure 8 This is a schematic diagram of the connection between the power module and the capacitor of the motor controller in the fourth embodiment of this application; Figure 9 for Figure 8 A schematic diagram of the structure of the capacitor 20.

[0110] In this embodiment, both the positive terminal 201 and the negative terminal 202 of the capacitor are provided with slots 20a. Figure 9 The free end of the positive terminal 201 of the capacitor has two oppositely distributed first terminal bifurcations 20121, and the free end of the negative terminal 202 of the capacitor has two oppositely distributed second terminal bifurcations 20221. A slot 20a is formed between the two first terminal bifurcations 20121 and the two second terminal bifurcations 20221. The second segment 1012 of the module positive terminal is inserted into the slot 20a of the positive terminal 201 of the capacitor, and the second segment 1022 of the module negative terminal is inserted into the slot 20a of the negative terminal 202 of the capacitor. After insertion, it can be an interference fit, so as to achieve an abutment connection along the thickness direction.

[0111] In the fourth embodiment, an elastic structure may also be provided between the inserted first terminal and the wall of the slot 20a. Specifically, an elastic structure may be provided between the second segment 1012 of the positive terminal of the module and the branch portion 20121 of the first terminal, and between the second segment 1022 of the negative terminal of the module and the branch portion 20221 of the second terminal. The elastic structure may be, for example, a spring sheet 502, to enhance the reliability of the contact.

[0112] like Figure 10 and Figure 11 As shown, Figure 10 This is a schematic diagram of the connection between the power module and the capacitor of the motor controller in the fifth embodiment of this application; Figure 11 for Figure 10 A schematic diagram of the structure of the medium power module 10.

[0113] The fifth embodiment is basically the same as the fourth embodiment, except that in the fourth embodiment, slot 20a is located in capacitor 20, while in the fifth embodiment, slot 10a is located in power module 10. Figure 10 Both the positive terminal 101 and the negative terminal 102 of the module are provided with slots 10a. The second segment 1012 of the positive terminal 101 and the second segment 1022 of the negative terminal 102 are directly bifurcated to form slots 10a. Similar to the fourth embodiment, the positive terminal 201 and the negative terminal 202 of the capacitor can be inserted into the corresponding slots 10a with an interference fit. Alternatively, an elastic structure can be provided between the first terminal of the capacitor 20 and the wall of the slot 10a.

[0114] This document uses specific examples to illustrate the principles and implementation methods of this application. The descriptions of the embodiments above are only for the purpose of helping to understand the method and core ideas of this application. It should be noted that those skilled in the art can make several improvements and modifications to this application without departing from the principles of this application, and these improvements and modifications also fall within the protection scope of the claims of this application.

Claims

1. A motor controller, characterized in that, It includes a power module (10) and a capacitor (20), both of which are provided with at least one pair of first terminals, each pair of first terminals including a positive terminal and a negative terminal; The capacitor (20) and the power module (10) are distributed along a first direction (Z), at least one pair of first terminals of the capacitor (20) extend out of the capacitor (20) along a second direction (Y), and at least one pair of first terminals of the power module (10) extend out of the power module (10) along the second direction (Y), and the first direction (Z) and the second direction (Y) intersect. The positive terminal of the capacitor (20) is connected to the positive terminal of the power module (10), and the negative terminal of the capacitor (20) is connected to the negative terminal of the power module (10).

2. The motor controller according to claim 1, characterized in that, The first terminal includes a first terminal segment and a second terminal segment connected to each other. The first terminal segment extends along the second direction (Y), and the second terminal segment is bent relative to the first terminal segment and extends along the first direction (Z). The second terminal of the positive terminal of the capacitor (20) and the second terminal of the positive terminal of the power module (10) are connected in abutment along the thickness direction, and the second terminal of the negative terminal of the capacitor (20) and the second terminal of the negative terminal of the power module (10) are connected in abutment along the thickness direction.

3. The motor controller according to claim 2, characterized in that, The motor controller includes a housing having a top and a bottom distributed along the first direction (Z), and a capacitor (20) supported at the bottom of the housing and glued to the housing.

4. The motor controller according to claim 3, characterized in that, The motor controller also includes a cooling component (30) located between the power module (10) and the capacitor (20) in the first direction (Z).

5. The motor controller according to any one of claims 1-4, characterized in that, At least one pair of the first terminals of the power module (10) are located between a pair of the first terminals of the corresponding capacitor (20); Alternatively, portions of at least one pair of the first terminals of the capacitor (20) may be located between a corresponding pair of the first terminals of the power module (10).

6. The motor controller according to any one of claims 1-4, characterized in that, At least one of the first terminals of the capacitor (20) is provided with a slot (20a), and the first terminal of the corresponding power module (10) is inserted into the slot (20a) of the corresponding capacitor (20). At least one of the first terminals of the power module (10) is provided with a slot (10a), and the first terminal of the corresponding capacitor (20) is inserted into the slot (20a) of the corresponding power module (10).

7. The motor controller according to claim 5 or 6, characterized in that, The first terminal of the capacitor (20) and the corresponding first terminal of the power module (20) are interference-fitted.

8. The motor controller according to any one of claims 1-6, characterized in that, The motor controller includes an elastic structure; at least one positive terminal of the capacitor (20) and the corresponding positive terminal of the power module (10) are pressed together by the elastic structure; at least one negative terminal of the capacitor (20) and the corresponding negative terminal of the power module (10) are pressed together by the elastic structure.

9. The motor controller according to any one of claims 1-4, characterized in that, At least one pair of the first terminals of the power module (10) are located between a pair of the first terminals of the corresponding capacitor (20), and the motor controller further includes an elastic structure located at least partially between a pair of the first terminals of the power module (10), the elastic structure pressing against the first terminals of the power module (10). Alternatively, portions of at least one pair of the first terminals of the capacitor (20) are located between a pair of the first terminals of the corresponding power module (10), and the motor controller further includes an elastic structure located at least partially between the pair of the first terminals of the capacitor (20), the elastic structure pressing against the first terminals of the capacitor (20).

10. The motor controller according to claim 9, characterized in that, The elastic structure is a spring sheet (502); or the elastic structure is an elastic pin (501).

11. The motor controller according to claim 10, characterized in that, Along the extension direction of the pair of first terminals directly pressed by the elastic pin (501), the cross-sectional size of the elastic pin (501) gradually increases.

12. The motor controller according to claim 11, characterized in that, The outer surface of at least the portion of the elastic pin (501) used to press against the first terminal is made of insulating material.

13. The motor controller according to claim 11, characterized in that, A portion of the elastic pin (501) is located between a pair of first terminals corresponding to the power module (10) and presses against a pair of first terminals of the power module (10); A portion of the resilient pin (501) is located between a pair of first terminals of the capacitor (20) and is connected to the pair of first terminals of the capacitor (20) by potting.

14. The motor controller according to any one of claims 1-13, characterized in that, The motor controller includes an insulating film (40), and the insulating film (40) is present between at least one pair of the first terminals.

15. The motor controller according to any one of claims 1-13, characterized in that, Each pair of the first terminals is arranged opposite to each other along the thickness direction of the first terminal.

16. The motor controller according to any one of claims 1-15, characterized in that, The first direction (Z) and the second direction (Y) are perpendicular.

17. An electric drive assembly, characterized in that, Including the motor controller described in any one of the above claims 1-16.

18. A vehicle, characterized in that, Includes the electric drive assembly described in claim 17.

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