New energy automobile motor controller structure
By setting up a separation cavity in the motor controller structure of the new energy vehicle, the controller and the motor are highly integrated and EMC isolation are achieved, which solves the problems of large space occupation and poor electromagnetic compatibility in traditional structures, and improves the anti-interference performance of the motor controller and security.
Patent Information
- Application Number
- CN202322567094.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Priority Date
- 2022-12-05
- Filing Date
- 2023-09-21
- Publication Date
- 2025-01-07
- Estimated Expiration
- 2033-09-21
AI Technical Summary
The structure of the motor controller of the traditional new energy vehicle is independent of the motor controller and the motor case, which occupies a large space, which limits the layout plan. In addition, low-voltage controllers, high-voltage DC devices, and three-phase AC devices are difficult to isolate, resulting in electromagnetic compatibility problems. Affects the safe and reliable operation of the motor controller.
By providing a rib plate on the bottom plate of the box to separate it into an adjacent first cavity and a second cavity, the control plate is arranged in the first cavity, the DC wiring base and the filter assembly are arranged in the second cavity, and the three-phase busbar is arranged in the third cavity, and the Set at the end of the box base plate, the controller and the motor are highly integrated, and the low-voltage device, high-voltage DC device, and three-phase AC device are arranged in different cavitys to achieve EMC isolation.
It realizes a high degree of integration between the controller and the motor, saves installation space, improves anti-interference performance, and ensures the safe and reliable operation of the motor controller.
Smart Images
Figure CN222321878U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of motor control, and in particular to a motor controller structure for a new energy vehicle. Background Art
[0002] The motor controller structure for traditional new energy vehicles usually has a closed box, in which DC terminals, filter components, DC busbars, film capacitors, high-voltage power boards, grounding busbars, drive modules, drive boards, control boards, current sensors and other components are distributed. These components are fixed inside the box by bolts, and together with the box and cover, they form a motor controller structure that meets the IPX7 airtight requirements. The above components are fixed inside the box by bolts to form a motor control assembly structure. Since the motor controller and the motor box are independent, the motor control assembly occupies a large space in the front of the vehicle, compressing the space for other components and limiting the layout of new energy vehicles. At the same time, due to the integration solution of the existing motor controller, it is difficult to isolate the low-voltage controller components, high-voltage DC devices, and three-phase AC devices to prevent mutual crosstalk, resulting in prominent electromagnetic compatibility issues and affecting the safe and reliable operation of the motor controller. Summary of the invention
[0003] The technical problem to be solved by the utility model is to provide a new energy vehicle motor controller structure. The structure realizes a high degree of integration between the controller and the motor, and the controller low-voltage devices, high-voltage DC devices, and three-phase AC devices are respectively arranged in different cavities to achieve EMC isolation, improve anti-interference performance, and ensure safe and reliable operation of the motor controller.
[0004] In order to solve the above technical problems, the utility model of the new energy vehicle motor controller structure includes a DC terminal, a filter component, a DC busbar, a control board, a film capacitor, a high-voltage power board, a ground busbar, a drive module, a drive board, a current sensor, a three-phase busbar and a box bottom plate. The front of the box bottom plate is enclosed and divided into an adjacent first cavity and a second cavity by a rib plate. The control board is arranged in the first cavity, the DC terminal, the DC busbar and the filter component are arranged in the second cavity, the three-phase busbar is arranged at the end of the box bottom plate and is located below the first cavity, the top surface of the first cavity is provided with a large cover plate, the top surface of the second cavity is provided with a DC cover plate, and the top surface of the three-phase busbar is provided with a three-phase cover plate; the drive board, the drive module, the current sensor, the film capacitor, the high-voltage power board and the ground busbar are openly arranged on the back of the box bottom plate.
[0005] Furthermore, the DC busbar is arranged on the DC terminal block, and the input end of the DC busbar is connected to the first filter busbar, and the output end is connected to the input end of the thin film capacitor and the input end of the filter component; the output end of the thin film capacitor is connected to the input end of the driving module and the busbar of the high-voltage power board; the grounding busbar is connected to the thin film capacitor and the high-voltage power board; the three-phase busbar of the driving module is connected to the current sensor, the high-voltage power board is connected to the thin film capacitor, the driving board is connected to the driving module, and the three-phase busbar is connected to the three-phase terminals of the motor.
[0006] Furthermore, a continuous mounting surface is provided around the bottom plate of the box body, a plurality of connection holes are provided at intervals on the mounting surface, and the bottom plate of the box body is connected to the motor housing through the mounting surface and the connection holes.
[0007] Furthermore, the DC terminal block includes an annular magnetic core, a first capacitor and a DC terminal block body, the first filter busbar is located above the DC terminal block body, the first capacitor is arranged below the DC terminal block body, and the annular magnetic core is built into the cavity of the DC terminal block body and is potted with epoxy glue.
[0008] Furthermore, the DC busbar passes through the inner ring of the annular magnetic core of the DC wiring socket.
[0009] Furthermore, the filter assembly includes a second filter busbar, a second capacitor and a PCBA board, the second filter busbar and the second capacitor are connected to the PCBA board, and the second capacitor is located below the PCBA board, the second filter busbar is located on the side of the second capacitor, and the filter assembly is installed in the second cavity through the PCBA board.
[0010] Furthermore, the motor controller structure also includes a box cooling channel, which is arranged in the box bottom plate, and the box cooling channel is respectively provided with a water inlet and a water outlet on the front and back of the box bottom plate, and the water inlet and the water outlet are respectively connected to the cooling circulation system.
[0011] Furthermore, the driving module is attached to the box cooling channel portion in the box bottom plate.
[0012] Furthermore, the water inlet is provided with a water nozzle.
[0013] Furthermore, a plurality of truncated cones are arranged at intervals on the top of the film capacitor, and the truncated cones are provided with concentric screw holes, and the top of the film capacitor is connected to the box body by bolts screwed into the screw holes; a plurality of bosses are arranged at intervals on the top of the film capacitor, and the surfaces of the bosses support the components on the back of the high-voltage power taking board by means of glue coating or thermal conductive silicone pads.
[0014] Since the utility model adopts the above technical solution, the front of the box bottom plate of the structure is enclosed and divided into the adjacent first cavity and the second cavity by the rib plate, the control board is arranged in the first cavity, the DC terminal block, the DC busbar and the filter assembly are arranged in the second cavity, the three-phase busbar is arranged at the end of the box bottom plate and below the first cavity, the top surface of the first cavity is provided with a large cover plate, the top surface of the second cavity is provided with a DC cover plate, and the top surface of the three-phase busbar is provided with a three-phase cover plate; the drive board, the drive module, the current sensor, the film capacitor, the high-voltage power board and the grounding busbar are arranged in an open manner on the back of the box bottom plate. This structure realizes the high integration of the controller and the motor, and the low-voltage components, high-voltage DC components and three-phase AC components of the controller are arranged in different cavities respectively, so as to realize EMC isolation, improve the anti-interference performance and ensure the safe and reliable operation of the motor controller. BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The present invention is further described in detail below in conjunction with the accompanying drawings and implementation examples:
[0016] Figure 1 This is a schematic diagram of the structure of the new energy vehicle motor controller of the utility model;
[0017] Figure 2 This is a front view of the bottom plate of the box in the motor controller structure;
[0018] Figure 3 This is a schematic diagram of the back side of the bottom plate of the box in the motor controller structure;
[0019] Figure 4 This is a schematic diagram of the DC wiring socket in the motor controller structure;
[0020] Figure 5 This is a schematic diagram of the filter component in the motor controller structure;
[0021] Figure 6 This is a schematic diagram of the box cooling flow channel in this motor controller structure.
[0022] Figure 7 This is a schematic diagram of the film capacitor structure in this motor controller structure. DETAILED DESCRIPTION
[0023] Implementation example Figure 1 , Figure 2 and Figure 3As shown, the structure of the new energy vehicle motor controller of the utility model includes a DC connection socket 14, a filter component 12, a DC busbar 15, a control board 16, a film capacitor 8, a high-voltage power board 6, a ground busbar 7, a drive module 11, a drive board 9, a current sensor 10, a three-phase busbar 17 and a box bottom plate 1. The front of the box bottom plate 1 is enclosed and divided into adjacent first cavities 32 and second cavities 33 by a rib plate 29. The control board 16 is arranged in the first cavity 32. The DC connection socket 14 , the DC busbar 15 and the filter assembly 12 are arranged in the second cavity 33, the three-phase busbar 17 is arranged at the end of the box bottom plate 1 and is located below the first cavity 32, the top surface of the first cavity 32 is provided with a large cover plate 3, the top surface of the second cavity 33 is provided with a DC cover plate 2, and the top surface of the three-phase busbar 17 is provided with a three-phase cover plate 4; the driving board 9, the driving module 11, the current sensor 10, the thin film capacitor 8, the high-voltage power board 6 and the grounding busbar 7 are openly arranged on the back of the box bottom plate 1.
[0024] Preferably, the DC busbar 15 is arranged on the DC terminal block 14, and the input end of the DC busbar 15 is connected to the first filter busbar 13, and the output end is connected to the input end of the thin film capacitor 8 and the input end of the filter component 12; the output end of the thin film capacitor 8 is connected to the input end of the drive module 11 and the busbar of the high-voltage power supply board 6; the grounding busbar 7 is connected to the thin film capacitor 8 and the high-voltage power supply board 6; the three-phase busbar 17 of the drive module 11 is connected to the current sensor 10, the high-voltage power supply board 6 is connected to the thin film capacitor 8, the drive board 9 is connected to the drive module 11, and the three-phase busbar 17 is connected to the three-phase terminals of the motor.
[0025] Preferably, a continuous mounting surface 30 is provided around the box bottom plate 1 , and a plurality of connection holes 31 are provided at intervals on the mounting surface 30 . The box bottom plate 1 is connected to the motor housing through the mounting surface 30 and the connection holes 31 .
[0026] Preferably, Figure 4 As shown, the DC terminal block 14 includes an annular magnetic core 21, a first capacitor 19 and a DC terminal block body 20, the first filter busbar 13 is located above the DC terminal block body 20, the first capacitor 19 is arranged below the DC terminal block body 20, and the annular magnetic core 21 is built into the cavity of the DC terminal block body 20 and is encapsulated with epoxy glue.
[0027] Preferably, the DC busbar 15 passes through the inner circle of the annular magnetic core 21 of the DC connection socket 14 .
[0028] Preferably, Figure 5As shown, the filter component 12 includes a second filter busbar 23, a second capacitor 24 and a PCBA board 22. The second filter busbar 23 and the second capacitor 24 are connected to the PCBA board 22, and the second capacitor 24 is located below the PCBA board 22. The second filter busbar 23 is located on the side of the second capacitor 24. The filter component 12 is installed in the second cavity through the PCBA board 22.
[0029] Preferably, Figure 6 As shown, the motor controller structure also includes a box cooling channel 27, which is arranged in the box bottom plate 1, and the box cooling channel 27 is provided with a water inlet 25 and a water outlet 26 on the front and back of the box bottom plate 1, respectively, and the water inlet 25 and the water outlet 26 are respectively connected to the cooling circulation system. The box cooling channel is used to dissipate heat for electrical components installed on the box bottom plate to ensure that the motor controller works at the rated temperature.
[0030] Preferably, the driving module 11 is close to the box cooling channel 27 in the box bottom plate 1. The driving module is the component with the highest heat generation in the motor controller. The driving module is preferably close to the box cooling channel to improve the cooling effect of the driving module.
[0031] Preferably, Figure 1 and Figure 2 As shown, the water inlet 25 is provided with a water nozzle 5. The water nozzle is convenient for connecting with the cooling water circulation system.
[0032] Preferably, Figure 7 As shown, a plurality of truncated terraces 81 are arranged at intervals on the top of the film capacitor 8, and the truncated terraces 81 are provided with concentric screw holes 82. The top of the film capacitor 8 is connected to the box body by bolts screwed into the screw holes 82; a plurality of bosses 83 are arranged at intervals on the top of the film capacitor 8, and the surface of the bosses 83 supports the components on the back of the high-voltage power taking board through glue coating or thermal conductive silicone pads.
[0033] The layout of this structure enables the mounting surface of the open bottom plate of the motor controller box to be directly mounted on the motor housing, thereby achieving a high degree of integration between the controller and the motor, saving installation space in the vehicle, and facilitating the flexible layout of the motor and controller in new energy vehicles. The low-voltage components and high-voltage components of the controller are arranged in different cavities, respectively, to achieve EMC isolation and anti-interference, thereby ensuring the safe and reliable operation of the motor controller.
Claims
1. A new energy vehicle motor controller, comprising a DC terminal block, a filter assembly, a DC busbar, a control board, a film capacitor, a high voltage power board, a ground busbar, a drive module, a drive board, a current sensor and a three-phase busbar, characterized in that: It also includes a box bottom plate, the front side of the box bottom plate is enclosed and divided into an adjacent first cavity and a second cavity by a rib plate, the control board is arranged in the first cavity, the DC terminal block, the DC busbar and the filter assembly are arranged in the second cavity, the three-phase busbar is arranged at the end of the box bottom plate and is located below the first cavity, the top surface of the first cavity is provided with a large cover plate, the top surface of the second cavity is provided with a DC cover plate, and the top surface of the three-phase busbar is provided with a three-phase cover plate; the drive board, drive module, current sensor, thin film capacitor, high-voltage power board and grounding busbar are openly arranged on the back side of the box bottom plate.
2. The new energy vehicle motor controller according to claim 1 is characterized in that: The DC busbar is arranged on the DC terminal block, and the input end of the DC busbar is connected to the first filter busbar, and the output end is connected to the input end of the thin film capacitor and the input end of the filter component; the output end of the thin film capacitor is connected to the input end of the driving module and the busbar of the high-voltage power board; the grounding busbar is connected to the thin film capacitor and the high-voltage power board; the three-phase busbar of the driving module is connected to the current sensor, the high-voltage power board is connected to the thin film capacitor, the driving board is connected to the driving module, and the three-phase busbar is connected to the three-phase terminals of the motor.
3. The new energy vehicle motor controller according to claim 1 or 2, characterized in that: A continuous mounting surface is arranged around the bottom plate of the box body, a plurality of connection holes are arranged at intervals on the mounting surface, and the bottom plate of the box body is connected to the motor housing through the mounting surface and the connection holes.
4. The new energy vehicle motor controller according to claim 2, characterized in that: The DC wiring socket includes an annular magnetic core, a first capacitor and a DC wiring socket body. The first filter busbar is located above the DC wiring socket body, the first capacitor is arranged below the DC wiring socket body, and the annular magnetic core is built into the cavity of the DC wiring socket body and is potted with epoxy glue.
5. The new energy vehicle motor controller according to claim 4 is characterized in that: The DC busbar passes through the inner ring of the annular magnetic core of the DC connection seat.
6. The new energy vehicle motor controller according to claim 1 or 2, characterized in that: The filter assembly includes a second filter busbar, a second capacitor and a PCBA board. The second filter busbar and the second capacitor are connected to the PCBA board, and the second capacitor is located below the PCBA board. The second filter busbar is located on the side of the second capacitor. The filter assembly is installed in the second cavity through the PCBA board.
7. The new energy vehicle motor controller according to claim 1 or 2, characterized in that: The motor controller structure also includes a box cooling channel, which is arranged in the box bottom plate, and the box cooling channel is respectively provided with a water inlet and a water outlet on the front and back of the box bottom plate, and the water inlet and the water outlet are respectively connected to the cooling circulation system.
8. The new energy vehicle motor controller according to claim 7, characterized in that: The driving module is attached to the box cooling channel in the box bottom plate.
9. The new energy vehicle motor controller according to claim 7, characterized in that: The water inlet is provided with a water nozzle.
10. The new energy vehicle motor controller according to claim 1, characterized in that: A plurality of truncated cones are arranged at intervals on the top of the film capacitor, and the truncated cones are provided with concentric screw holes. The top of the film capacitor is connected to the box body by screwing bolts into the screw holes; a plurality of bosses are arranged at intervals on the top of the film capacitor, and the surfaces of the bosses support the components on the back of the high-voltage power board through glue coating or thermal conductive silicone pads.