Generator controller of extended-range electric vehicle
By using copper refrigeration boxes and heat exchange components in the extended-range electric vehicle generator controller, the problem of poor heat dissipation effect of existing controllers is solved, and more efficient heat dissipation is achieved, which extends the equipment life and reduces costs. .
Patent Information
- Application Number
- CN202420795508.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-04-17
- Publication Date
- 2025-02-21
- Estimated Expiration
- 2034-04-17
AI Technical Summary
The existing extended-range electric vehicle generator controller has poor heat dissipation effect and low efficiency, which makes it difficult to effectively dissipate heat generated by the internal components of the controller.
A copper refrigeration box is used as a heat exchange component. The inverter module is installed at the top of the refrigeration box. Heat transfer and heat dissipation are used (including water pipes and arc-shaped tubes) to improve the heat dissipation effect inside the control box.
Through the heat absorption effect of the copper refrigeration box and the design of the heat exchange component, the internal heat dissipation effect of the controller is significantly improved, the service life of the controller is extended, and the operating cost is reduced.
Smart Images
Figure CN222515460U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to a range-extended electric vehicle generator controller, belonging to the field of generator controllers. Background Art
[0002] The range extender of new energy vehicles solves the problem that electric vehicles cannot drive when they are out of power and are troublesome to charge. When the on-board power battery is out of power, the electric vehicle can be driven and the battery can be charged without stopping. It greatly expands the range of electric vehicles and truly achieves continuous driving without mileage restrictions. As long as there is a gas station, you can reach any place you want to go. In addition, it is particularly important that electric vehicles equipped with range extenders can extend the service life of power batteries by more than 3 times, greatly reducing the cost of battery use.
[0003] The range-extended generator is a generator that outputs DC power to drive the electric vehicle's drive motor without stopping the vehicle while the electric vehicle is in motion, and controls the generator voltage to be stable within the standard range, and the remaining power is used to charge the battery. Therefore, there is no need to worry about the damage to the vehicle battery pack caused by excessive voltage and high current charging. The control strategy of the generator controller intelligently controls the generator to replenish power to the electric vehicle power battery in a timely manner at the best charging state, eliminating the heat caused by over-discharge and over-charging of the electric vehicle power battery, and the consumption of electrolyte boiling and evaporation, so that the power battery is always kept in the best use state, thereby extending the service life of the power battery. However, when the range-extended generator controller is working for a long time, the heat generated by the internal components of the controller needs to be dissipated by timely heat exchange, but the existing controller has poor heat dissipation and low efficiency. Therefore, this application proposes a range-extended electric vehicle generator controller with a heat exchange block. Utility Model Content
[0004] In view of the deficiencies in the prior art, the utility model aims to provide a range-extended electric vehicle generator controller.
[0005] In order to achieve the above purpose, the utility model is implemented through the following technical solutions:
[0006] A range-extended electric vehicle generator controller comprises a mounting plate, a control box is fixedly provided on the mounting plate, a shielding plate, a control board, an inverter module, and a DC support capacitor are arranged in the control box, a power terminal of the inverter module is connected to a power line terminal through a copper bus, the control board is mounted on the shielding plate, the inverter module is mounted on the top of a refrigeration box, the refrigeration box is made of a heat-absorbing copper box, a heat exchange component is arranged in the refrigeration box, a plurality of extension components are fixedly provided on the heat exchange component, the extension components each comprise two water pipes, and the top ends of the water pipes are connected by an arc pipe.
[0007] Furthermore, the inverter module adopts a two-in-one single-phase bridge arm integrated power module, and the power module unit in the inverter module is welded with a driving board.
[0008] Furthermore, the heat exchange component includes multiple upper refrigeration tubes and lower refrigeration tubes, the upper refrigeration tubes are connected by connecting tubes, the lower refrigeration tubes are connected by secondary connecting tubes, and one of the upper refrigeration tubes and one of the lower refrigeration tubes are connected by a connecting tube.
[0009] Furthermore, a circulation pipe is formed between the upper refrigeration pipe, the connecting pipe, the connecting pipe, the lower refrigeration pipe and the secondary connecting pipe, one end of one of the upper refrigeration pipes passes through the control box and is a water inlet pipe, and one end of one of the lower refrigeration pipes passes through the control box and is a water outlet pipe.
[0010] Furthermore, the lower refrigeration pipe of the water outlet pipe is connected to a water tank, a water pump is fixedly connected to the upper surface of the water tank, the water inlet pipe of the water pump is connected to the water suction pipe on the water tank, the bottom of the water suction pipe penetrates into the bottom of the water tank, the water outlet pipe of the water pump is connected to the water inlet pipe of the refrigerator, and the water outlet pipe of the refrigerator is connected to the upper refrigeration pipe of the water outlet pipe.
[0011] Furthermore, a telescopic hose is provided at one end of the water outlet pipe of the refrigerator, one end of the telescopic hose is a hard tube, one end of the upper refrigeration tube of the water inlet pipe is inserted into the telescopic hose, a sealing ring 1 is provided on the inner side of the telescopic hose, a mounting tube is fixedly provided on the outer surface of the water outlet pipe of the refrigerator, and a sealing ring 2 is provided on the outer surface of the telescopic hose.
[0012] Furthermore, a locking screw is threadedly inserted on the installation cylinder, and a circular ring is fixedly sleeved on the outer surface of the telescopic hose, and a threaded hole corresponding to the locking screw is sleeved on the circular ring.
[0013] Beneficial effects of the utility model:
[0014] In the present application, the refrigeration box is made of a heat-absorbing copper box, that is, a copper plate box. The electronic equipment inside the control box generates temperature when working. The copper refrigeration box has a good heat absorption effect, and the inverter module is installed on the top of the refrigeration box, so it has a good thermal conductivity effect, and the heat can be transferred to the heat exchange component, thereby completing the heat exchange effect, and greatly improving the heat dissipation effect inside the control box. The protruding component is designed on the heat exchange component. It can be directly seen from the figure that some water pipes and arc pipes pass through the refrigeration box and are exposed inside the control box. The cooling water generated inside the water pipes and arc pipes will also absorb the heat inside the control box, thereby improving the heat exchange effect. BRIEF DESCRIPTION OF THE DRAWINGS
[0015] In order to more clearly illustrate the embodiments of the utility model or the technical solutions in the prior art, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the utility model. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.
[0016] Figure 1 This is a front view of a range-extended electric vehicle generator controller according to the utility model;
[0017] Figure 2 It is a schematic diagram of the extension component of a range-extended electric vehicle generator controller of the utility model;
[0018] Figure 3 This is a schematic diagram of the interior of a refrigeration box of a range-extended electric vehicle generator controller according to the utility model;
[0019] Figure 4 The utility model is a schematic diagram of a telescopic hose of a range-extended electric vehicle generator controller.
[0020] In the figure: 1. mounting plate; 2. control box; 3. shielding plate; 4. control board; 5. inverter module; 6. DC support capacitor; 7. power line terminal; 8. water pipe; 9. arc pipe; 10. upper cooling pipe; 11. lower cooling pipe; 12. connecting pipe; 13. connecting pipe; 14. water tank; 15. water pump; 16. refrigerator; 17. water suction pipe; 18. telescopic hose; 19. sealing ring 1; 20. mounting tube; 21. sealing ring 2; 22. locking screw; 23. ring; 24. threaded hole; 25. refrigeration box. DETAILED DESCRIPTION
[0021] The following will be combined with the drawings in the embodiments of the utility model to clearly and completely describe the technical solutions in the embodiments of the utility model. Obviously, the described embodiments are only part of the embodiments of the utility model, not all of the embodiments. Based on the embodiments in the utility model, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the utility model.
[0022] See also Figure 1-4The utility model provides a technical solution: a range-extended electric vehicle generator controller, comprising a mounting plate 1, a control box 2 is fixedly provided on the mounting plate 1, a shielding plate 3, a control board 4, an inverter module 5, and a DC support capacitor 6 are arranged in the control box 2, the power terminal of the inverter module 5 is connected to the power line terminal 7 through a copper bar, the control board 4 is mounted on the shielding plate 3, the inverter module 5 is mounted on the top of a refrigeration box 25, the refrigeration box 25 is made of a heat-absorbing copper box, a heat exchange component is arranged in the refrigeration box 25, a plurality of protruding components are also fixedly provided on the heat exchange component, and the protruding components each include two water pipes 8, and the tops of the water pipes 8 are connected by an arc pipe 9.
[0023] See also Figure 1 The inverter module 5 adopts a two-in-one single-phase bridge arm integrated power module. The power module unit in the inverter module 5 is welded with a drive board. The drive signal line between the power module in the inverter module 5 and the drive board is short, and the reliability is high. The power terminal in the inverter module 5 is directly connected to the power line terminal through a copper bus. The entire controller has a simple structure, which is easy to produce, install and maintain, and has low cost. There is a shielding plate between the control board and the inverter module. The shielding plate uses a heat-insulating and magnetic-insulating composite material. The system is heat-insulated and magnetic-insulated, and has high reliability. The DC support capacitor adopts a customized automotive film capacitor. The film capacitor integrates DC positive and negative laminated busbars, which is small in size, small in parasitic inductance, high reliability and low cost.
[0024] See also Figure 1-3 The heat exchange assembly includes a plurality of upper refrigeration tubes 10 and lower refrigeration tubes 11, wherein the upper refrigeration tubes 10 are connected to each other through a connecting tube 12, and the lower refrigeration tubes 11 are connected to each other through a secondary connecting tube. One of the upper refrigeration tubes 10 and one of the lower refrigeration tubes 11 are connected to each other through a connecting tube 13. A circulation tube is formed between the upper refrigeration tube 10, the connecting tube 12, the connecting tube 13, the lower refrigeration tube 11 and the secondary connecting tube. One end of one of the upper refrigeration tubes 10 passes through the The control box 2 is a water inlet pipe, one end of one of the lower refrigeration pipes 11 passes through the control box 2 and is a water outlet pipe. The lower refrigeration pipe 11 which is a water outlet pipe is connected to a water tank 14. A water pump 15 is fixedly connected to the upper surface of the water tank 14. The water inlet end pipe of the water pump 15 is connected to a water suction pipe 17 on the water tank 14. The bottom of the water suction pipe 17 penetrates into the bottom of the water tank 14. The water outlet end pipe of the water pump 15 is connected to the water inlet end pipe of the refrigerator 16. The water outlet end pipe of the refrigerator 16 is connected to the upper refrigeration pipe 10 which is a water outlet pipe.
[0025] The water inlet end pipe of the water pump 15 is connected to the water suction pipe 17, so the water inside the water tank 14 is pumped into the refrigerator 16, the refrigerator 16 cools the water and then sends it into the upper cooling pipe 10 which is the water inlet pipe, the water inside the upper cooling pipe 10 is interconnected along the connecting pipe 12, the heat conducted by the refrigeration box 25 can be cooled along the upper cooling pipe 10 for cooling, and the cooled water will also enter the lower cooling pipe 11 along the connecting pipe 13, so the pipeline between the lower cooling pipe 11 and the upper cooling pipe 10 forms a circulation pipe, and the heat exchange water finally flows into the water tank again from the lower cooling pipe 11 of the water outlet pipe, and is then pumped into the refrigerator 16 for circulating cooling, and the cooled water will also enter the water pipe 8 and the arc tube 9, further improving the heat exchange performance.
[0026] See also Figure 1 and Figure 4 A telescopic hose 18 is provided at one end of the water outlet pipe of the refrigerator 16, and one end of the telescopic hose 18 is a hard pipe, and one end of the upper refrigeration pipe 10 of the water inlet pipe is inserted into the telescopic hose 18, and a sealing ring 19 is provided on the inner side of the telescopic hose 18. A mounting tube 20 is fixedly sleeved on the outer surface of the water outlet pipe of the refrigerator 16, and a sealing ring 21 is provided on the outer surface of the telescopic hose 18. A locking screw 22 is threadedly inserted on the mounting tube 20, and a circular ring 23 is fixedly sleeved on the outer surface of the telescopic hose 18, and a threaded hole 24 corresponding to the locking screw 22 is sleeved on the circular ring 23.
[0027] One end of the upper refrigeration pipe 10 of the water inlet pipe is inserted into the telescopic hose 18, that is, inserted into the hard tube of the telescopic hose 18. The designed sealing rings 1 and 2 are designed on the hard tube. After insertion, the outer surface of the inserted end of the water inlet pipe will be tightly wrapped by the sealing ring 1. At this time, the installation tube 20 will also wrap the sealing ring 21, and the sealing ring 21 is tightly attached to the inside of the installation tube 20 to ensure the sealed connection between the two. Because the car is vibrating when driving, the connection between the two pipes needs to have good sealing performance, and also needs to ensure subsequent disassembly, because after the designed equipment is damaged, it needs to be disassembled for convenient maintenance, and it needs to be returned to the factory for replacement and repair when necessary.
[0028] The water inlet end pipe of the water pump 15 is connected to the water suction pipe 17, and the connection method between them can adopt the above-mentioned design method.
[0029] The connection between the refrigerator 16 and the water pump 15 may also adopt the above-mentioned design.
[0030] During specific operation, the present application uses a refrigeration box 25 made of a heat-absorbing copper box, that is, a copper plate box. The electronic equipment inside the control box 2 generates temperature when working. The copper refrigeration box 25 has a good heat absorption effect, and the inverter module 5 is installed on the top of the refrigeration box 25, so it has a good thermal conductivity effect, and the heat can be transferred to the heat exchange component, thereby completing the heat exchange effect, and greatly improving the heat dissipation effect inside the control box 2. The protruding component is designed on the heat exchange component. It can be directly seen from the figure that part of the water pipe 8 and the arc tube 9 pass through the refrigeration box 25 and are exposed inside the control box 2. The cooling water generated inside the water pipe 8 and the arc tube 9 will also absorb the heat inside the control box 2, thereby improving the heat exchange effect.
[0031] Part of the water pipe 8 and the arc-shaped pipe 9 passes through the refrigeration box 25 , and the passing portion is designed not to block or affect the arrangement of the components inside the control box 2 .
[0032] Although this specification is described according to implementation modes, not every implementation mode includes only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment may also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.
Claims
1. A range-extended electric vehicle generator controller, characterized in that: The invention comprises a mounting plate (1), a control box (2) is fixedly provided on the mounting plate (1), a shielding plate (3), a control board (4), an inverter module (5), and a DC support capacitor (6) are arranged in the control box (2), a power terminal of the inverter module (5) is connected to a power line terminal (7) through a copper bar, the control board (4) is mounted on the shielding plate (3), the inverter module (5) is mounted on the top of a refrigeration box (25), the refrigeration box (25) is made of a heat-absorbing copper box, a heat exchange component is arranged in the refrigeration box (25), and a plurality of extension components are fixedly provided on the heat exchange component, each of the extension components comprises two water pipes (8), and the top ends of the water pipes (8) are connected by an arc pipe (9).
2. The range-extended electric vehicle generator controller according to claim 1, characterized in that: The inverter module (5) adopts a two-in-one single-phase bridge arm integrated power module, and a power module unit in the inverter module (5) is welded with a drive board.
3. The range-extended electric vehicle generator controller according to claim 2, characterized in that: The heat exchange component comprises a plurality of upper refrigeration tubes (10) and lower refrigeration tubes (11); the upper refrigeration tubes (10) are connected to each other via a connecting tube (12); the lower refrigeration tubes (11) are connected to each other via a secondary connecting tube; and one of the upper refrigeration tubes (10) and one of the lower refrigeration tubes (11) are connected to each other via a connecting tube (13).
4. The range-extended electric vehicle generator controller according to claim 3, characterized in that: A circulation pipe is formed between the upper refrigeration pipe (10), the connecting pipe (12), the connecting pipe (13), the lower refrigeration pipe (11) and the auxiliary connecting pipe, one end of the upper refrigeration pipe (10) passes through the control box (2) and serves as a water inlet pipe, and one end of the lower refrigeration pipe (11) passes through the control box (2) and serves as a water outlet pipe.
5. The range-extended electric vehicle generator controller according to claim 4, characterized in that: The lower refrigeration pipe (11) serving as a water outlet pipe is connected to a water tank (14); a water pump (15) is fixedly connected to the upper surface of the water tank (14); a water inlet pipe of the water pump (15) is connected to a water suction pipe (17) on the water tank (14); the bottom of the water suction pipe (17) penetrates into the bottom of the water tank (14); the water outlet pipe of the water pump (15) is connected to the water inlet pipe of a refrigerator (16); and the water outlet pipe of the refrigerator (16) is connected to the upper refrigeration pipe (10) serving as a water outlet pipe.
6. A range-extended electric vehicle generator controller according to claim 5, characterized in that: A telescopic hose (18) is provided at one end of the water outlet pipe of the refrigerator (16), one end of the telescopic hose (18) is a hard pipe, and one end of the upper refrigeration pipe (10) of the water inlet pipe is inserted into the telescopic hose (18), and a sealing ring 1 (19) is provided on the inner side of the telescopic hose (18). A mounting sleeve (20) is fixedly provided on the outer surface of the water outlet pipe of the refrigerator (16), and a sealing ring 2 (21) is provided on the outer surface of the telescopic hose (18).
7. A range-extended electric vehicle generator controller according to claim 6, characterized in that: A locking screw (22) is threadedly inserted on the installation cylinder (20), and a circular ring (23) is fixedly sleeved on the outer surface of the telescopic hose (18), and a threaded hole (24) corresponding to the locking screw (22) is sleeved on the circular ring (23).