Split shell motor controller

Abstract

The utility model discloses a split shell motor controller, a controller shell is provided with a first area and a second area which are separated by a lower retaining wall, a controller upper cover is provided with an upper retaining wall which is arranged with the lower retaining wall in a crossed and staggered manner, and a filtering assembly is arranged in the first area. The second area of the controller shell is of a partition structure with the high-voltage current trend and the low-voltage current trend being parallel, the PCBA board is a drive and control integrated board, is arranged on the top layer of the IGBT board and is provided with a control board area arranged in the high-voltage current trend and a drive board area arranged in the low-voltage current trend, and a circuit of the drive board area is electrically connected with the IGBT board. The control panel area circuit is electrically connected with the low-voltage wire harness assembly and the rotary transformer wire harness assembly. The IGBT plate is located on the cooling pool, and the cooling part of the IGBT plate extends into the cooling liquid of the cooling pool. The utility model provides a water channel integration and lightweight design thought, reduces the number of parts, assembly procedures and production line investment, and reduces the process difficulty.

Description

Technical Field

[0001] The utility model relates to an electric drive assembly of a new energy vehicle, in particular to a motor controller in the electric drive assembly. Background Art

[0002] With the rapid development of the new energy vehicle industry, the entire vehicle has also put forward requirements for the electric drive assembly, such as lightweight, integration, and intelligence. Among them, integration requires the electric drive assembly structure to be lighter and more flexible.

[0003] In the current internal structure layout of automobile controllers, the path design from the high-voltage DC input to the AC output is complex.

[0004] The use of copper bars often results in the controller being too large and having low power density. At the same time, the isolation design between the high-voltage circuit and the low-voltage circuit is not sufficient, there are too many internal adapter harnesses, and the EMC performance is poor.

[0005] In order to improve the EMC effect of the controller, the internal drive PCBA and control PCBA of the controller are separated, and a metal shielding plate is used to shield the high-voltage signal to improve the EMC effect. However, the use of shielding plates and too many AC copper bars can easily cause the problem of low vibration resistance of the controller.

[0006] The above layout can be found in Chinese patent document CN 215872091 U, which generally has disadvantages such as a large number of parts, complex internal wiring, and low volume utilization. These disadvantages will cause the controller to be large in size, heavy in weight, high in cost, and have many assembly processes. Utility Model Content

[0007] The utility model aims at providing a split-shell motor controller to optimize the structural layout of the controller and save space.

[0008] To this end, the utility model provides a split shell motor controller, including a controller housing, a controller cover, a filter component, a film capacitor, an IGBT board, a PCBA board, a low-voltage wiring harness assembly, a resolver wiring harness assembly, and a three-phase fixed seat. The controller housing has a first area and a second area separated by a lower retaining wall, and the controller cover is provided with an upper retaining wall arranged crosswise and displaced with the lower retaining wall. The filter component is arranged in the first area, and the second area of ​​the controller housing is a high-voltage current direction and a low-voltage current direction are parallel and parallel partition structures. The film capacitor, the IGBT board and the three-phase fixed seat are arranged in the second area in sequence along the high-voltage current direction, and the low-voltage wiring harness assembly and the resolver wiring harness assembly are arranged in sequence in the second area along the low-voltage current direction. The PCBA board is a drive control integrated board, which is arranged on the top layer of the IGBT board, and has a control board area arranged along the high-voltage current direction and a drive board area arranged along the low-voltage current direction. The drive board area circuit is electrically connected to the IGBT board, and the control board area circuit is electrically connected to the low-voltage wiring harness assembly and the resolver wiring harness assembly respectively.

[0009] Furthermore, the lower retaining wall includes a partition retaining wall extending around the periphery of the low-voltage wiring harness assembly to separate the low-voltage wiring harness assembly from peripheral high-voltage devices.

[0010] Furthermore, the IGBT board is seated on the cooling pool and its heat dissipation portion extends into the coolant in the cooling pool, and an IGBT sealing element is provided between the cooling pool and the IGBT board.

[0011] Furthermore, the cooling pool is integrally formed with the bottom wall of the controller housing, and a water inlet channel and a water outlet channel connected to the cooling pool are formed in the bottom wall of the controller housing, the water inlet channel is provided with a water inlet nozzle, and the water outlet channel is provided with a water outlet.

[0012] Furthermore, the water inlet and the water outlet are both arranged on the bottom surface of the controller.

[0013] Furthermore, a film capacitor thermal pad is provided between the film capacitor and the bottom wall of the controller housing.

[0014] Furthermore, the bottom copper busbar of the three-phase fixing seat, the low-voltage wiring harness assembly, and the external terminals of the resolver wiring harness assembly are arranged on the bottom surface of the controller housing.

[0015] Furthermore, the above-mentioned filter assembly is electrically connected to a busbar arranged laterally relative to the controller housing.

[0016] According to the structural layout of the motor controller of the utility model, the assembly of the internal components of the controller is convenient, space is saved, and the power density is improved. At the same time, the process difficulty and cost investment of the production line can be reduced; the high and low voltage partition layout is adopted to reduce the intersection of high and low voltage partitions and improve the EMC performance; retaining walls are set between the upper cover and the controller shell, and the retaining walls are cross-staggered to wrap the low-voltage wiring harness to improve the EMC performance; the water cooling pool is integrated on the shell to reduce the number of internal components of the controller and simplify the assembly process of the controller.

[0017] In addition to the above-described purposes, features and advantages, the present invention has other purposes, features and advantages. The present invention will be further described in detail below with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The drawings constituting part of the present application are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation on the present invention. In the drawings:

[0019] Figure 1 It is an exploded diagram of the structure of the split shell motor controller of the utility model;

[0020] Figure 2 It is a three-dimensional structural schematic diagram of the split shell motor controller of the utility model, wherein the upper cover has been removed;

[0021] Figure 3 This is the current trend diagram of the split shell motor controller of the utility model;

[0022] Figure 4 It is a schematic diagram of the bottom surface of the split shell motor controller housing of the utility model;

[0023] Figure 5 The internal retaining wall structure of the split shell motor controller of the utility model is shown;

[0024] Figure 6 A schematic diagram of the housing structure of the split-shell motor controller of the utility model is shown;

[0025] Figure 7 A schematic diagram of the upper cover structure of the split shell motor controller of the utility model is shown;

[0026] Figure 8 The figure shows the matching relationship between the IGBT board and the cooling pool in the split-shell motor controller of the utility model. DETAILED DESCRIPTION

[0027] The present invention will be described in detail below with reference to the accompanying drawings and in combination with embodiments.

[0028] Combined with reference Figures 1 to 8The split shell motor controller of the utility model includes an upper cover 1, a film capacitor thermal pad 2, an IGBT sealing ring 3, an IGBT board 4, a PCBA board 5, a three-phase fixing seat 6, a three-phase fixing seat sealing ring 7, a rotating transformer wiring harness assembly 8, a water inlet 9, a controller housing 10, a low-voltage wiring harness assembly 11, a filter component 12, a film capacitor 13, a small cover plate 14, a water outlet 15, and a busbar 16.

[0029] The housing 10 is divided into a first area 10b and a second area 10c by a lower retaining wall 10a. The first area 10b is provided with a filter assembly 12. The controller upper cover 1 is provided with an upper retaining wall 1a which is parallel to and cross-staggered with the lower retaining wall 10a.

[0030] The lower retaining wall 10a is composed of a partition retaining wall 10a1 (two retaining walls) extending on the periphery of the low-voltage wiring harness assembly 11 and a straight retaining wall 10a2. The partition retaining wall 10a1 is used to separate the low-voltage wiring harness assembly 11 from the peripheral high-voltage devices (filter component 12 and film capacitor 13).

[0031] The second zone 10c of the controller housing is a partition structure in which the high-voltage current direction and the low-voltage current direction are parallel and arranged in parallel. A thin-film capacitor 13, an IGBT board 4, and a three-phase fixing seat 6 are arranged in sequence along the high-voltage current direction, and a low-voltage wiring assembly 11 and a resolver wiring harness assembly 8 are arranged along the low-voltage current direction, wherein the low-voltage wiring harness assembly 11 is arranged adjacent to the first zone 10b, and the resolver wiring harness assembly 8 and the three-phase fixing seat 6 are arranged side by side.

[0032] The PCBA board 5 is arranged on the top layer of the IGBT board 4. The PCBA board 5 is an integrated drive and control board, including a drive board area arranged along the direction of high-voltage current and a control board area arranged along the direction of low-voltage current. The drive board area circuit is electrically connected to the IGBT board, and the control board area circuit is electrically connected to the low-voltage wiring harness assembly 11 and the resolver wiring harness assembly 8.

[0033] On the entire controller housing, the high-voltage current flows through the busbar 16 - filter component 12 - film capacitor 13 - IGBT board 4 - three-phase fixing seat 6, and the low-voltage current flows through the low-voltage line assembly 11 - control board area of ​​the PCBA board 5 - resolver harness assembly 8.

[0034] Since the high-voltage current and the low-voltage current are in a parallel partition structure, the intersection of high and low voltage paths is reduced, and the EMC performance of the motor controller is improved. Compared with the existing technology, the shielding plate is eliminated, the number of internal components and assembly processes of the controller are reduced, and the vibration resistance of the controller is improved.

[0035] A film capacitor thermal pad 2 is provided between the film capacitor 13 and the bottom wall of the controller housing 10 to enhance the heat dissipation effect of the film capacitor 13 .

[0036] The IGBT board 5 is located on the cooling pool 10d and the heat dissipation part (e.g., heat dissipation column array) of the IGBT board 5 extends into the coolant in the cooling pool 10d to dissipate a large amount of heat generated when the IGBT board 5 is working. An IGBT sealing element 7, such as a sealing ring, is provided between the IGBT boards 5 to prevent the coolant from entering the housing space outside the cooling pool.

[0037] The cooling pool 10d is integrally formed with the bottom wall of the controller housing 10, and a water inlet channel and a water outlet channel connected to the cooling pool are integrally formed in the bottom wall of the controller housing. The water inlet channel and the water outlet channel refer to the manufacturing method of the hydraulic valve body channel, so that the water inlet nozzle 9 and the water outlet 16 can be arranged at the specified position on the bottom wall or side wall of the housing.

[0038] The water inlet 9 and the water outlet 16 are arranged on the bottom surface of the controller housing 10. At the same time, the external copper busbar of the three-phase fixed seat 6, the low-voltage harness assembly 11 and the external plug / socket of the resolver harness assembly 8 are arranged on the bottom surface of the controller housing.

[0039] The assembly sequence of the motor controller is as follows: first fix the resolver harness assembly 8, the water inlet nozzle 9, and the low-voltage harness assembly 11 to the controller housing 10, fix the filter assembly 12 to the controller housing 10, assemble the film capacitor thermal pad 2 and the film capacitor 13 to the controller housing 10, assemble the IGBT seal ring 3 and the IGBT board 4 to the controller housing 10, assemble the three-phase fixed seat seal ring 7 and the three-phase fixed seat 6 to the controller housing 10, and then assemble the PCBA board 5 to the controller housing 10, and finally assemble the upper cover plate 1 and the small cover plate 14 in sequence. The above assembly sequence can be adjusted according to different schemes.

[0040] Since the controller cover 1 and the controller housing 10 are provided with retaining walls 1a and 10a1 inside, after the cover 1 and the housing 10 are assembled, the retaining walls are parallel, cross-staggered and structurally wrapped around the low-voltage harness assembly 11, reducing the interference of high-voltage signals outside and inside the controller, and cooperating with the high-low voltage partition of the PCBA to avoid the problem of high-low voltage crossover, further improving the EMC performance. Through this structural method, the shielding plate of the low-voltage harness assembly can be omitted, the number of internal components of the controller can be reduced, and the power density can be improved.

[0041] The above description is only an embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A split-shell motor controller, comprising a controller housing, a controller cover, a filter assembly, a film capacitor, an IGBT board, a PCBA board, a low-voltage wiring harness assembly, a resolver wiring harness assembly, and a three-phase fixing seat, characterized in that: The controller housing has a first area and a second area separated by a lower retaining wall, an upper retaining wall arranged crosswise and staggered with the lower retaining wall is provided on the upper cover of the controller, and the filter assembly is arranged in the first area. The second area of ​​the controller housing is a partition structure in which the high-voltage current direction and the low-voltage current direction are parallel and parallel, and the film capacitor, IGBT board and three-phase fixing seat are arranged in the second area in sequence along the high-voltage current direction. The low-voltage wiring harness assembly and the resolver wiring harness assembly are sequentially arranged in the second zone along the low-voltage current direction. The PCBA board is an integrated drive control board, which is arranged on the top layer of the IGBT board. It has a control board area arranged along the direction of high-voltage current and a drive board area arranged along the direction of low-voltage current. The drive board area circuit is electrically connected to the IGBT board, and the control board area circuit is electrically connected to the low-voltage wiring harness assembly and the resolver wiring harness assembly respectively.

2. The split housing motor controller according to claim 1, characterized in that: The lower retaining wall includes a partition retaining wall extending at the periphery of the low-voltage wiring harness assembly to separate the low-voltage wiring harness assembly from peripheral high-voltage devices.

3. The split housing motor controller according to claim 1, characterized in that: The IGBT board is seated on the cooling pool and its heat dissipation portion extends into the coolant in the cooling pool. An IGBT sealing element is arranged between the cooling pool and the IGBT board.

4. The split housing motor controller according to claim 3, characterized in that: The cooling pool is integrally formed with the bottom wall of the controller housing, and a water inlet channel and a water outlet channel connected to the cooling pool are formed in the bottom wall of the controller housing. The water inlet channel is provided with a water inlet nozzle, and the water outlet channel is provided with a water outlet.

5. The split housing motor controller according to claim 4, characterized in that: The water inlet and the water outlet are both arranged on the bottom surface of the controller.

6. The split housing motor controller according to claim 1, characterized in that: A film capacitor heat-conducting pad is arranged between the film capacitor and the bottom wall of the controller housing.

7. The split housing motor controller according to claim 1, characterized in that: The bottom copper bar of the three-phase fixing seat, the low-voltage wiring harness assembly, and the external terminals of the resolver wiring harness assembly are arranged on the bottom surface of the controller housing.

8. The split housing motor controller according to claim 1, characterized in that: The filter assembly is electrically connected to a bus bar arranged laterally relative to the controller housing.

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