Motor controller and automobile
Through the single-sided welding of capacitor terminals and multi-layer conductive strips and the direct potting design of capacitors, the problems of many welding processes and the inability to pot the capacitors in the motor controller are solved, and the effect of reducing costs and improving performance is achieved.
Patent Information
- Application Number
- CN202420581125.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-03-25
- Publication Date
- 2025-01-07
- Estimated Expiration
- 2034-03-25
AI Technical Summary
The existing motor controllers require double-sided welding when laying out power modules in layered arrangement, resulting in many welds and welding processes, high process costs, and the capacitor cannot be directly filled into the controller housing.
The capacitor terminal is welded with a multi-layer conductive strip. The number of conductive strips is two layers, arranged in a stacked layer, and the capacitor is directly potted into the controller housing to reduce welding process and process costs.
Single-sided welding is realized, which reduces weld and process costs, improves product volume power density, and reduces equivalent series inductance through stacked conductive strips, thereby improving capacitance performance.
Smart Images
Figure CN222321901U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of inverters, in particular to a motor controller and a car. Background Art
[0002] With the iterative development of the electric vehicle industry, the technical trend of the overall structure of the motor controller is characterized by miniaturization, light weight, high power density, and high integration. The electrical connection method of the core components is one of the core concerns of miniaturization.
[0003] The motor controller in the related art often has capacitors encapsulated in a plastic shell, and the positive and negative terminals of the capacitors each use two layers of wires, which are then welded to copper bars respectively. Each copper bar then corresponds to a different power module, and the whole is fixed to the controller housing through the installation angle of the plastic shell. Therefore, the motor controller in the related art needs double-sided welding for power modules that need to be arranged in layers, and the motor controller after double-sided welding has the defects of more welds, more welding steps, and high process cost. Summary of the invention
[0004] In view of the above shortcomings of the prior art, the purpose of the utility model is to provide a motor controller and a car, in which a single side of the capacitor terminal of the motor controller is welded to a multi-layer conductive row body, thereby reducing welds and welding procedures and lowering process costs.
[0005] The utility model discloses a motor controller, which includes:
[0006] A capacitor having single rows of capacitor terminals at different polarities of the capacitor;
[0007] A conductive conductor, wherein the conductive conductor comprises a multi-layer conductive array, and a single side of the capacitor terminal is welded to the multi-layer conductive array; and
[0008] The controller housing, the capacitor is potted in the controller housing.
[0009] Furthermore, the conductive conductor includes a positive conductor and a negative conductor, and the capacitor terminal includes a positive capacitor terminal and a negative capacitor terminal; wherein the positive conductor is welded to the positive capacitor terminal, and the negative conductor is welded to the negative capacitor terminal.
[0010] Furthermore, the number of the conductive array bodies is two layers, and the two layers of conductive array bodies are connected to each other and are stacked.
[0011] Furthermore, the two layers of conductive busbars are mirror-symmetrical along their connection planes.
[0012] Furthermore, the conductive bar body includes a conductive copper bar and / or a conductive aluminum bar.
[0013] Furthermore, a plating layer is provided on the surface of the conductive busbar.
[0014] Furthermore, the motor controller also includes a heat dissipation module and a plurality of power modules. The plurality of power modules are distributed on two opposite sides of the heat dissipation module, and the positive and negative terminals of the power modules are electrically connected to the multi-layer conductive bus.
[0015] Furthermore, the controller housing has an opening on one side, and the welding side of the capacitor terminal faces the opening.
[0016] Furthermore, the motor controller also includes a power module, and the multi-layer conductive bus is respectively connected to different power modules.
[0017] The embodiment of the utility model also discloses a car, comprising the motor controller as described above.
[0018] The motor controller provided by the utility model has the following beneficial effects, including but not limited to:
[0019] 1) The motor controller can use the single-layer outlet arrangement of the capacitor terminal and the layered arrangement of the conductive conductor, so that the conductive conductor used to connect multiple power modules can be welded to the capacitor terminal on one side, thereby reducing the welds and welding procedures and reducing the process cost; at the same time, the conductive conductor is welded to the capacitor terminal on one side, so that the capacitor can be directly potted in the controller housing, thereby further reducing the process cost and improving the product volume power density;
[0020] 2) In the motor controller, the number of conductive arrays is two, and the two layers of conductive arrays are interconnected and stacked. This arrangement can reduce the equivalent series inductance, thereby improving the performance of the capacitor in the circuit;
[0021] 3) In the motor controller, multiple power modules are interconnected with the conductive row body, and the heat dissipation module is arranged between the multiple power modules, which can further improve the heat dissipation efficiency of the power modules. BRIEF DESCRIPTION OF THE DRAWINGS
[0022] This specification will be further described in the form of exemplary embodiments, which will be described in detail by the accompanying drawings. These embodiments are not restrictive, and in these embodiments, the same number represents the same structure, wherein:
[0023] Figure 1 It is a connection diagram of a motor controller in the related art;
[0024] Figure 2 A schematic diagram of the connection at the negative capacitor terminal in the motor controller provided by an embodiment of the utility model;
[0025] Figure 3A schematic diagram of the welding area of a motor controller provided in an embodiment of the utility model;
[0026] Figure 4 One of the schematic diagrams of the arrangement of the power module and the heat dissipation module provided in the embodiment of the utility model;
[0027] Figure 5 The second schematic diagram of the arrangement of the power module and the heat dissipation module provided in the embodiment of the utility model.
[0028] Icon: 100-motor controller; 10-capacitor; 101-capacitor terminal; 11-conductive row; 12-controller housing; 121-opening; 13-power module; 14-heat dissipation module. DETAILED DESCRIPTION
[0029] The following describes the implementation of the present invention through specific examples, and those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. The present invention can also be implemented or applied through other different specific implementations, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the following embodiments and features in the embodiments can be combined with each other without conflict.
[0030] It should be noted that the illustrations provided in the following embodiments are only used to schematically illustrate the basic concept of the present invention, and thus the illustrations only show components related to the present invention rather than being drawn according to the number, shape and size of components in actual implementation. In actual implementation, the type, quantity and proportion of each component may be changed arbitrarily, and the component layout may also be more complicated.
[0031] Figure 1 The figure is a connection diagram of a motor controller in the related art. The capacitor of the motor controller in the related art is encapsulated in a plastic shell, and the positive and negative terminals of the capacitor each use two layers of wires. The whole can be fixed on the controller housing through the installation angle of the plastic shell. Figure 1 As shown, taking the welding of capacitor T-terminals as an example, the process flow mainly includes: ① front laser welding T-soft copper bus terminal and capacitor T-copper bus terminal ——> ② back laser welding T-soft copper bus terminal and capacitor T-copper bus terminal ——> the entire assembly is installed in the controller housing and connected with screws.
[0032] From the above analysis, it can be seen that this process has at least the following disadvantages:
[0033] 1) Long process flow, mainly reflected in the large number of welding steps and welds; 2) High cost, mainly reflected in the large number of steps for welding soft copper bars, which increases process cost; material cost of capacitors (i.e. material cost of plastic shell); additional material cost of controller shell (material cost of bolt connection structure in controller shell). 3) Large space occupation, mainly reflected in the space of capacitor plastic shell; process space for screwing; 4) Low volume power density of products.
[0034] At the same time, by Figure 1 It can be seen that the connection technology of the products in the related art only considers the connection of a single-layer copper busbar, and the connection design mode needs to connect the positive and negative terminals from two aspects (front welding direction and back welding direction). Therefore, it cannot meet the demand of directly encapsulating the capacitor in the controller housing (most of the existing controller housings have only one side opening and cannot adopt double-sided welding process).
[0035] like Figure 2 and Figure 3 As shown, the embodiment of the utility model provides a motor controller 100, which includes a capacitor 10, a conductive conductor and a controller housing 12. The capacitor 10 has single-row capacitor terminals 101 at different polarities. The conductive conductor has a multi-layer conductive row body 11, and a single side of the capacitor terminal 101 is welded to the multi-layer conductive row body 11. The capacitor 10 is potted in the controller housing 12.
[0036] It is worth noting that the motor controller 100 can, through the single-layer wire output setting of the capacitor terminal 101 and the layered setting of the conductive conductor, enable the conductive conductor used to connect multiple power modules to be welded to the capacitor terminal 101 on one side, thereby reducing welds and welding steps and reducing process costs; at the same time, the conductive conductor is welded to the capacitor terminal 101 on one side, so that the capacitor 10 can be directly encapsulated in the controller housing 12 (that is, after the capacitor 10 is directly encapsulated in the controller housing 12, the conductive conductor can be connected to the capacitor terminal 101 by single-sided welding), thereby further reducing process costs and improving product volume power density.
[0037] Figure 2 The connection diagram of the negative capacitor terminal 101 in the motor controller 100 provided in the embodiment of the utility model is as follows. It can be understood that the conductive conductor includes a positive conductor and a negative conductor, the capacitor terminal 101 includes a positive capacitor terminal and a negative capacitor terminal, the positive conductor is welded to the positive capacitor terminal, and the negative conductor is welded to the negative capacitor terminal.
[0038] Please refer again Figure 2 The conductive conductor includes a multi-layer conductive array 11 , and each of the multi-layer conductive array 11 is welded to the capacitor terminal 101 on one side.
[0039] It is worth noting that the arrangement of the multi-layer conductive row 11 can increase the contact area of the connection, reduce the possibility of loose connection, and thus improve the reliability and stability of the connection. At the same time, the multi-layer conductive row 11 can increase the conductivity, carry a larger current load, reduce resistance, reduce the heat of the line, and ensure the stability and safety of current transmission.
[0040] In this embodiment, the number of the conductive array 11 is two layers, and the two layers of conductive arrays 11 are connected to each other and are stacked. It can be understood that after welding, the stacked conductive array 11 can reduce the equivalent series inductance (ESL), so that the capacitor 10 has a lower impedance in the high frequency range, thereby improving its performance in the high frequency circuit, helping to reduce the resonance frequency of the capacitor 10, and improving the stability and reliability of the circuit.
[0041] like Figure 2 As shown, the two layers of conductive arrays 11 are mirror-symmetrical along their connection plane. It is understandable that by arranging the conductive arrays 11 in mirror-symmetrical fashion, the current distribution of the conductive arrays 11 on both sides can be ensured to be more uniform, reducing the heat concentration problem caused by current unevenness, thereby improving the stability and reliability of the circuit.
[0042] In this embodiment, the conductive bar 11 includes a conductive copper bar and / or a conductive aluminum bar. Depending on the specific implementation environment, the conductive bar 11 can also be made of other conductive materials. This embodiment is only an example of its material and does not constitute a specific limitation on its material type.
[0043] Meanwhile, a coating may be provided on the surface of the conductive row 11. It is understood that the coating may improve its conductivity, corrosion resistance, contact performance, aesthetics and weldability, thereby improving the stability, reliability and overall performance of the circuit.
[0044] Please refer again Figure 2 The controller housing 12 has an opening 121 on one side, and the welding side of the capacitor terminal 101 is opposite to the opening 121. It is worth noting that the housing opening 121 is opposite to the housing opening 121, which can facilitate the use of front laser welding of the conductive bus 11 (T-soft copper bus terminal) and the negative capacitor terminal 101 (capacitor T-copper bus terminal), thereby reducing the welding process and improving the product volume power density.
[0045] Please refer to Figure 4 and Figure 5 , Figure 4 One of the schematic diagrams (side view) of the arrangement of the power module and the heat dissipation module provided in the embodiment of the utility model; Figure 5The second schematic diagram (top view) of the arrangement of the power module and the heat dissipation module provided in the embodiment of the utility model. The motor controller also includes a heat dissipation module 14 and a plurality of power modules 13, and the plurality of power modules 13 are distributed on the opposite two side surfaces of the heat dissipation module 14, and the positive and negative terminals of the power modules 13 are electrically connected to the multi-layer conductive row body 11. In this embodiment, the heat dissipation module 14 can be a cooling water channel. Depending on the specific implementation environment, the heat dissipation module can also adopt other structural types, as long as it can achieve the heat dissipation effect on the power modules 13 on both sides. This embodiment does not constitute a limitation on the specific structural type of the heat dissipation module, but is only an example thereof.
[0046] The embodiment of the utility model further provides a car, comprising the motor controller 100 as described above, having all the beneficial effects thereof.
[0047] The above embodiments are merely illustrative of the principles and effects of the present invention, and are not intended to limit the present invention. Anyone familiar with the technology may modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by a person of ordinary skill in the art without departing from the spirit and technical concept disclosed in the present invention shall still be covered by the claims of the present invention.
[0048] In the description herein, many specific details, such as examples of components and / or methods, are provided to provide a complete understanding of the embodiments of the present invention. However, those skilled in the art will recognize that embodiments of the present invention may be practiced without one or more specific details or by other devices, systems, components, methods, components, materials, parts, etc. In other cases, well-known structures, materials, or operations are not specifically shown or described in detail to avoid obscuring aspects of the embodiments of the present invention.
[0049] References throughout the specification to "one embodiment," "an embodiment," or "a specific embodiment" mean that a particular feature, structure, or characteristic described in conjunction with the embodiment is included in at least one embodiment of the present invention, and not necessarily in all embodiments. Thus, various appearances of the phrases "in one embodiment," "in an embodiment," or "in a specific embodiment" in different places throughout the specification do not necessarily refer to the same embodiment. In addition, the particular features, structures, or characteristics of any specific embodiment of the present invention may be combined with one or more other embodiments in any suitable manner. It should be understood that other variations and modifications of the embodiments of the present invention described herein and shown may be based on the teachings herein and will be considered part of the spirit and scope of the present invention.
[0050] It should also be understood that one or more of the elements shown in the figures may also be implemented in a more separate or more integrated manner, or even removed because they are inoperable in certain circumstances or provided because they may be useful depending on the application.
[0051] In addition, unless otherwise explicitly indicated, any marking arrows in the drawings should be regarded as exemplary only and not limiting. In addition, unless otherwise indicated, the term "or" used herein is generally intended to mean "and / or". In the case where the term is not clear because it is anticipated that the ability to separate or combine is provided, the combination of components or steps will also be regarded as indicated.
[0052] As used in the description herein and throughout the claims that follow, "a", "an", and "the" include plural references unless otherwise indicated. Likewise, as used in the description herein and throughout the claims that follow, the meaning of "in" includes "in" and "on" unless otherwise indicated.
[0053] The above description of the illustrated embodiments of the present invention (including the contents in the abstract of the specification) is not intended to be an exhaustive list or to limit the present invention to the precise form disclosed herein. Although specific embodiments of the present invention and examples of the present invention are described herein for illustrative purposes only, various equivalent modifications are possible within the spirit and scope of the present invention as will be recognized and understood by those skilled in the art. As noted, these modifications may be made to the present invention in accordance with the above description of the embodiments of the present invention, and these modifications will be within the spirit and scope of the present invention.
[0054] Systems and methods have been generally described herein as details that are helpful for understanding the present invention. In addition, various specific details have been given to provide an overall understanding of the embodiments of the present invention. However, those skilled in the relevant art will recognize that the embodiments of the present invention can be practiced without one or more specific details, or practiced using other devices, systems, accessories, methods, components, materials, parts, etc. In other cases, well-known structures, materials, and / or operations are not specifically shown or described in detail to avoid confusion with various aspects of the embodiments of the present invention.
Claims
1. A motor controller, characterized in that: include: A capacitor, wherein different polarities of the capacitor are provided with single-row capacitor terminals respectively; A conductive conductor, wherein the conductive conductor has a multi-layer conductive array, and a single side of the capacitor terminal is welded to the multi-layer conductive array; and A controller housing, wherein the capacitor is encapsulated in the controller housing.
2. The motor controller according to claim 1, characterized in that: The conductive conductor includes a positive conductor and a negative conductor, and the capacitor terminal includes a positive capacitor terminal and a negative capacitor terminal; wherein the positive conductor is welded to the positive capacitor terminal, and the negative conductor is welded to the negative capacitor terminal.
3. The motor controller according to claim 1, characterized in that: The number of the conductive array bodies is two layers, and the two layers of the conductive array bodies are connected to each other and are stacked.
4. The motor controller according to claim 3, characterized in that: The two layers of conductive bars are mirror-symmetrical along their connection planes.
5. The motor controller according to claim 1, characterized in that: The conductive bar body includes a conductive copper bar and / or a conductive aluminum bar.
6. The motor controller according to claim 1, characterized in that: The surface of the conductive row body is provided with a plating layer.
7. The motor controller according to claim 1, characterized in that: The motor controller further comprises a heat dissipation module and a plurality of power modules. The plurality of power modules are distributed on two opposite sides of the heat dissipation module, and the positive and negative terminals of the power modules are electrically connected to the multi-layer conductive bus.
8. The motor controller according to claim 1, characterized in that: The controller housing has an opening on one side, and the welding side of the capacitor terminal faces the opening.
9. A car, characterized in that: The automobile comprises a motor controller as claimed in any one of claims 1 to 8.