Filtering assembly and motor controller

Abstract

The utility model provides a filtering assembly which comprises a direct-current copper bar and a filtering capacitor, the filtering capacitor is a capacitor core, the direct-current copper bar is provided with a welding position through hole, and the capacitor core and the direct-current copper bar are connected at the welding position through hole through metal welding; a heat insulation layer is arranged outside the capacitor core; the capacitor also comprises an injection molding housing, and the capacitor core and the DC copper bar are arranged in the injection molding housing. The filter capacitor does not need to be packaged independently, the thin-film capacitor core of the filter capacitor is directly connected with the direct-current copper bar in a welded mode, connection features on the copper bar and connection pins of the filter capacitor in the prior art are omitted, space is saved, the structural features are compact, and the space utilization rate is high; due to the fact that no extra capacitor pin exists, the loop path is short, capacitance stray inductance is small, and the EMC filtering effect is good.

Description

Technical Field

[0001] The present invention relates to the technical field of filters, and in particular to a filter component and a motor controller. Background Art

[0002] The motor control DC (direct current) high voltage side connection requires the design of a multi-stage filter to meet the functional requirements of EMC (electromagnetic compatibility). The filter mainly includes X and Y capacitors, copper busbar components and their magnetic rings, etc.

[0003] See attached Figure 1-3 Most of the existing EMC solutions for electric control use an injection-molded copper busbar, and then assemble the individually packaged film capacitors onto the copper busbar assembly for welding. The main problems are: (1) The filter capacitors are assembled onto the plastic parts and fixed with glue, which is a complicated process. (2) The filter capacitor pins and the copper busbar grounding point are connected by resistance welding; the pins are long, the inductance is large, and the filtering effect is poor; and the connection feature between the copper busbar and the XY capacitor increases the outer boundary size of the copper busbar, which greatly increases the cost. In addition, due to the influence of the welding process, this feature is difficult to manufacture and needs to be flattened first and then stamped. Summary of the invention

[0004] In order to overcome the above technical defects, the object of the present invention is to provide a filter component and a motor controller with high integration, simple manufacturing process and low noise.

[0005] The invention discloses a filter component, comprising a DC copper busbar and a filter capacitor, wherein the filter capacitor is a capacitor core, the DC copper busbar is provided with a welding position through hole, the capacitor core and the DC copper busbar are connected by metal welding at the welding position through hole; a heat insulation layer is provided outside the capacitor core; and an injection molded shell is also included, wherein the capacitor core and the DC copper busbar are arranged in the injection molded shell.

[0006] Preferably, the filter capacitor is a safety capacitor, including an X capacitor and a Y capacitor, and the Y capacitor is arranged in pairs.

[0007] Preferably, the DC copper bar includes a positive copper bar and a negative copper bar; the positive copper bar and the negative copper bar are stacked; the Y capacitor includes a pair of high-voltage Y capacitors and a pair of low-voltage Y capacitors, the two high-voltage Y capacitors are respectively connected to the positive copper bar and the negative copper bar; the two low-voltage Y capacitors are respectively connected to the positive copper bar and the negative copper bar; the X capacitor is arranged between the high-voltage Y capacitor and the low-voltage Y capacitor, and the X capacitor is connected to the positive copper bar and the negative copper bar.

[0008] Preferably, the positive copper bar is bent to a side away from the negative copper bar for a preset distance and then bent again to be parallel to the negative copper bar, and the negative copper bar is bent to a side away from the positive copper bar for a preset distance and then bent again to be parallel to the positive copper bar, thereby forming an accommodation gap between the positive copper bar and the negative copper bar, and the X capacitor is arranged in the accommodation gap.

[0009] Preferably, a support sheet (bent convex sheet) is provided at the bottom of the positive copper bar and the negative copper bar, and the support sheet is perpendicular to the positive copper bar and the negative copper bar; the position of the support sheet corresponds to the position of the welding position through hole, and the Y capacitor is placed on the support sheet.

[0010] Preferably, the welding position through hole of the positive copper busbar for connecting the high-voltage Y capacitor is staggered with the welding position through hole of the negative copper busbar for connecting the high-voltage Y capacitor; the welding position through hole of the positive copper busbar for connecting the low-voltage Y capacitor is staggered with the welding position through hole of the negative copper busbar for connecting the low-voltage Y capacitor.

[0011] Preferably, it also includes a grounding copper sheet, which is connected to the capacitor core by metal welding; a mounting hole is provided on the injection-molded housing, and the grounding copper sheet is fixed in the mounting hole.

[0012] Preferably, the welding position through hole is U-shaped.

[0013] Preferably, the heat insulation layer is made of foamed silicone material.

[0014] The invention also discloses a motor controller, comprising the above-mentioned filter component.

[0015] Compared with the prior art, the above technical solution has the following beneficial effects:

[0016] 1. The filter capacitor does not need to be packaged separately, and the film capacitor core of the filter capacitor is directly welded to the DC copper busbar, omitting the connection features on the copper busbar and the connection pins of the filter capacitor in the prior art, saving space, with compact structure and high space utilization; since there is no additional capacitor pin, the loop path is short, the capacitor inductance is small, and the EMC filtering effect is good;

[0017] 2. The welded filter capacitor and DC copper busbar are injection molded together, with high vibration reliability;

[0018] 3. The outer layer of the capacitor core is wrapped with heat-insulating material to reduce the thermal impact of the high-temperature injection molding process on the capacitor core. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a copper bar injection molded part of the prior art;

[0020] Figure 2 It is a structural schematic diagram of welding a copper bar injection molded part and a capacitor packaging part in the prior art;

[0021] Figure 3 It is a structural schematic diagram of the connection features on the copper busbar in the prior art;

[0022] Figure 4 A schematic diagram of the structure of a DC copper busbar provided by the present invention;

[0023] Figure 5 A schematic diagram of the structure of the welding position through hole on the DC copper busbar provided by the present invention;

[0024] Figure 6 A schematic diagram of the structure of the DC copper busbar and the capacitor core metal welding provided by the present invention;

[0025] Figure 7 This is a schematic diagram of the structure of the DC copper bus and capacitor core after injection molding packaging provided by the present invention.

[0026] Among them: 1-DC copper bus, 2-filter capacitor, 201-X capacitor, 202-Y capacitor, 3-connection feature, 4-soldering position through hole, 5-grounding copper sheet, 6-support sheet. DETAILED DESCRIPTION

[0027] The advantages of the present invention are further described below in conjunction with the accompanying drawings and specific embodiments.

[0028] Exemplary embodiments will be described in detail herein, examples of which are shown in the accompanying drawings. When the following description refers to the drawings, the same numbers in different drawings represent the same or similar elements unless otherwise indicated. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with the present disclosure. Instead, they are merely examples of devices and methods consistent with some aspects of the present disclosure as detailed in the appended claims.

[0029] The terms used in this disclosure are for the purpose of describing specific embodiments only and are not intended to limit the disclosure. The singular forms of "a", "said" and "the" used in this disclosure and the appended claims are also intended to include plural forms unless the context clearly indicates otherwise. It should also be understood that the term "and / or" used herein refers to and includes any or all possible combinations of one or more associated listed items.

[0030] It should be understood that although the terms first, second, third, etc. may be used in the present disclosure to describe various information, such information should not be limited to these terms. These terms are only used to distinguish the same type of information from each other. For example, without departing from the scope of the present disclosure, the first information may also be referred to as the second information, and similarly, the second information may also be referred to as the first information. Depending on the context, the word "if" as used herein may be interpreted as "at the time of" or "when" or "in response to determining".

[0031] In the description of the present invention, it is necessary to understand that the terms "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0032] In the description of the present invention, unless otherwise specified and limited, it should be noted that the terms "installed", "connected" and "connected" should be understood in a broad sense. For example, it can be a mechanical connection or an electrical connection, or it can be the internal connection between two components. It can be a direct connection or an indirect connection through an intermediate medium. For ordinary technicians in this field, the specific meanings of the above terms can be understood according to the specific circumstances.

[0033] In the following description, the suffixes such as "module", "component" or "unit" used to represent elements are only used to facilitate the description of the present invention, and have no specific meanings. Therefore, "module" and "component" can be used interchangeably.

[0034] See attached Figure 1-3 The assembly process of the filter assembly in the prior art includes: copper busbar injection molding; capacitor packaging; capacitor assembly to the copper busbar injection molding; welding the connection feature 3 on the copper busbar to the pins on the capacitor.

[0035] See attached Figure 4-7 The present invention discloses a filter assembly, including a DC copper busbar 1 and a filter capacitor 2. Compared with the prior art, the packaging link of the filter capacitor 2 is eliminated, and only the capacitor core is used. The capacitor core is first welded to the copper busbar without injection molding, and then injection molding is performed together, which simplifies the steps of the manufacturing process. More importantly, since the capacitor core and the copper busbar can be directly welded, the connection feature 3 on the copper busbar can be omitted, thereby reducing the space size; and since there is no additional capacitor pin, the loop path is short, the capacitor inductance is small, and the EMC filtering effect is good.

[0036] For details, see the attached Figure 4 , 5 7. The filter capacitor 2 of the present invention is a capacitor core, and a welding position through hole 4 is provided on the DC copper busbar 1. The welding position through hole 4 is used to accommodate metal solder, so that the capacitor core and the DC copper busbar 1 can be connected by metal welding at the welding position through hole 4.

[0037] See attached Figure 6 After the capacitor core and the DC copper busbar 1 are welded, they need to be injection molded so that the capacitor core and the DC copper busbar 1 are placed in the same injection molded shell. The injection molding temperature is usually high, and the working temperature of the capacitor core is usually lower than this temperature, so the capacitor core needs to be insulated during injection molding. Benfang adopts the method of setting a heat insulation layer outside the capacitor core for heat insulation to prevent damage to the capacitor core during the injection molding process.

[0038] Preferably, the welding position through hole 4 is U-shaped, so that you can stably weld and fix the capacitor core and the DC copper bus 1.

[0039] Preferably, the heat insulation layer is made of foamed silicone material. After the capacitor core and the DC copper bus 1 are welded, the foamed silicone is sprayed on the outer surface of the capacitor core to make it evenly distributed on the outer surface of the capacitor core to achieve the effect of heat insulation.

[0040] Furthermore, the filter capacitor 2 is a safety capacitor, including an X capacitor 201 and a Y capacitor 202 . The Y capacitors 202 are arranged in pairs, usually two Y capacitors 202 or four Y capacitors 202 .

[0041] The DC copper bar 1 includes a positive copper bar and a negative copper bar, and the positive copper bar and the negative copper bar are stacked. The Y capacitor 202 includes a pair of high-voltage Y capacitors 202 (i.e., two high-voltage Y capacitors 202) and a pair of low-voltage Y capacitors 202 (i.e., two low-voltage Y capacitors 202), one of the two high-voltage Y capacitors 202 is connected to the positive copper bar, and the other is connected to the negative copper bar; one of the two low-voltage Y capacitors 202 is connected to the positive copper bar, and the other is connected to the negative copper bar. The X capacitor 201 is connected to the positive copper bar and the negative copper bar, that is, the positive electrode of the X capacitor 201 is connected to the positive copper bar, and the negative electrode is connected to the negative copper bar.

[0042] Preferably, the high-voltage Y capacitor 202 and the low-voltage Y capacitor 202 are respectively arranged at two ends of the DC copper bus 1 , and the X capacitor 201 is arranged between the high-voltage Y capacitor 202 and the low-voltage Y capacitor 202 .

[0043] Specifically, the positive copper bar is bent to a preset distance away from the negative copper bar, and then bent again to be parallel to the negative copper bar. The negative copper bar is bent to a preset distance away from the positive copper bar, and then bent again to be parallel to the positive copper bar, so as to form an accommodation gap between the positive copper bar and the negative copper bar, and the X capacitor 201 is arranged in the accommodation gap. Two high-voltage Y capacitors 202 are respectively arranged on the side of the positive copper bar away from the negative copper bar, and on the side of the negative copper bar away from the positive copper bar. Two low-voltage Y capacitors 202 are also respectively arranged on the side of the positive copper bar away from the negative copper bar, and on the side of the negative copper bar away from the positive copper bar.

[0044] Furthermore, a support sheet 6 is provided at the bottom of the positive copper bar and the negative copper bar. The support sheet 6 is perpendicular to the positive copper bar and the negative copper bar, and can be understood as a bent convex sheet at the bottom of the copper bar. The position of the support sheet 6 corresponds to the position of the welding position through hole 4, that is, the copper bar above the position where the support sheet 6 is provided is provided with a welding position through hole 4, and the support sheet 6 is used to support the Y capacitor 202. In a preferred embodiment of the present invention, two support sheets 6 are provided at both ends of the positive copper bar, and two support sheets 6 are also provided at both ends of the negative copper bar.

[0045] Preferably, the welding position through hole 4 of the positive copper busbar for connecting the high-voltage Y capacitor 202 is staggered with the welding position through hole 4 of the negative copper busbar for connecting the high-voltage Y capacitor 202; the welding position through hole 4 of the positive copper busbar for connecting the low-voltage Y capacitor 202 is staggered with the welding position through hole 4 of the negative copper busbar for connecting the low-voltage Y capacitor 202, so as to disperse the connection stress borne by the copper busbar.

[0046] It also includes a grounding copper sheet 5, which is also connected to the capacitor core by metal welding. A mounting hole is provided on the injection molded shell. One end of the grounding copper sheet 5 is welded to the capacitor core, and the other end is fixed in the mounting hole (displayed on the injection molded shell for subsequent connection).

[0047] During processing, the capacitor core and the DC copper bus 1 are first welded, and then the capacitor core and the DC copper bus 1 are injection molded. Compared with the four process steps in the prior art, the present invention only requires two steps to achieve stable assembly, and omits the connection feature 3 on the DC copper bus 1, so that the entire structure size is smaller, the loop path is short, the capacitor inductance is small, and the EMC filtering effect is good.

[0048] The invention also discloses a motor controller, comprising the above-mentioned filter component.

[0049] It should be noted that the embodiments of the present invention have better practicability and do not impose any form of limitation on the present invention. Any technician familiar with the field may use the technical content disclosed above to change or modify it into an equivalent effective embodiment. However, any modification or equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. A filter component, characterized in that: It includes a DC copper busbar and a filter capacitor, wherein the filter capacitor is a capacitor core, the DC copper busbar is provided with a welding position through hole, and the capacitor core and the DC copper busbar are connected at the welding position through hole by metal welding; The capacitor core is provided with a heat insulation layer outside; It also includes an injection molded shell, in which the capacitor core and the DC copper bus are arranged.

2. The filter assembly according to claim 1, characterized in that: The filter capacitor is a safety capacitor, including an X capacitor and a Y capacitor, and the Y capacitor is arranged in pairs.

3. The filter assembly according to claim 2, characterized in that: The DC copper bar comprises a positive copper bar and a negative copper bar; the positive copper bar and the negative copper bar are stacked; The Y capacitor includes a pair of high-voltage Y capacitors and a pair of low-voltage Y capacitors, the two high-voltage Y capacitors are connected to the positive copper bar and the negative copper bar respectively; the two low-voltage Y capacitors are connected to the positive copper bar and the negative copper bar respectively; The X capacitor is disposed between the high-voltage Y capacitor and the low-voltage Y capacitor, and the X capacitor is connected to the positive copper busbar and the negative copper busbar.

4. The filter assembly according to claim 3, characterized in that: The positive copper bar is bent to a side away from the negative copper bar for a preset distance and then bent again to be parallel to the negative copper bar. The negative copper bar is bent to a side away from the positive copper bar for a preset distance and then bent again to be parallel to the positive copper bar, thereby forming an accommodation gap between the positive copper bar and the negative copper bar, and the X capacitor is arranged in the accommodation gap.

5. The filter assembly according to claim 4, characterized in that: A support sheet is provided at the bottom of the positive copper bar and the negative copper bar, and the support sheet is perpendicular to the positive copper bar and the negative copper bar; The position of the support sheet corresponds to the position of the soldering position through hole, and the Y capacitor is placed on the support sheet.

6. The filter assembly according to claim 5, characterized in that: The welding position through hole of the positive copper busbar used for connecting the high-voltage Y capacitor is staggered with the welding position through hole of the negative copper busbar used for connecting the high-voltage Y capacitor; The welding position through hole of the positive copper busbar used for connecting the low-voltage Y capacitor is staggered with the welding position through hole of the negative copper busbar used for connecting the low-voltage Y capacitor.

7. The filter assembly according to claim 1 or 6, characterized in that: It also includes a grounding copper sheet, which is connected to the capacitor core by metal welding; The injection molded housing is provided with a mounting hole, and the grounding copper sheet is fixed in the mounting hole.

8. The filter assembly according to claim 1, characterized in that: The welding position through hole is U-shaped.

9. The filter assembly according to claim 1, characterized in that: The heat insulation layer is made of foamed silica gel material.

10. A motor controller, characterized in that: The filter assembly comprises any one of claims 1 to 9.

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