Motor controller and double-sided water-cooling power module thereof
By setting up a cross-connected AC copper bar in the capacitor housing of the motor controller and filling it with the capacitor, the cantilever support is cancelled and the structure is simplified, and the complexity and welding problems caused by the independent existence of AC copper bars in the prior art are solved, and a simpler and more suitable motor controller design is achieved.
Patent Information
- Application Number
- CN202421898670.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-08-07
- Publication Date
- 2025-03-28
- Estimated Expiration
- 2034-08-07
AI Technical Summary
In existing motor controllers, AC copper bars exist independently, with complex structure and large volume, and need to cross the two sides of power bricks, resulting in complex design and high mold opening costs. The laser welding process is sensitive to high dimensions, which is prone to poor welding.
A double-sided water-cooled power module is designed. By setting up a cross-acrylic copper bar in the capacitor housing and filling it with the capacitor, the jumping cantilever support on the top of the capacitor is cancelled, the structure is simplified, the overall vibration strength is enhanced, and the position of the cross-acrylic copper bar is fixed through the fixed seat to ensure the control of the connection size.
The fixing and connection of AC copper rows is made simpler and more controllable, reducing the design size and height tolerance, reducing the risk of poor welding, and improving the adaptability of the overall structure and the simplicity of the process.
Smart Images
Figure CN222691611U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of motor controllers, in particular to a motor controller and a double-sided water-cooled power module thereof. Background Art
[0002] With the development of new energy vehicles, the dual-motor controller used in hybrid vehicles generally has two sets of power units and corresponding capacitors, and the connection with the motor assembly relies on AC copper busbar as the interface.
[0003] In the prior art, the AC copper busbar exists independently and is assembled with the power unit through a housing and / or other structural parts. The structure is complex and the volume is large. The AC copper busbar needs to bridge the two sides of the power brick to connect the three-phase module copper terminals. The span is long and the structure is complex. Different AC copper busbars need to be designed for different motor assembly AC interfaces, and the mold opening cost is high. In addition, when laser welding is used in the welding process of the AC copper busbar, the copper busbar exists independently and needs to be assembled, resulting in a long height dimension chain. Laser welding is sensitive to height dimensions. When there is a deviation in the height dimension, poor welding such as cold solder joints are prone to occur. Summary of the invention
[0004] In order to overcome the above technical defects, the purpose of the utility model is to provide a double-sided water-cooled power module for a motor controller with strong adaptability and simple process.
[0005] The utility model discloses a double-sided water-cooled power module for a motor controller, comprising: a capacitor housing, a DC capacitor is arranged in the capacitor housing, and power modules are arranged on both sides of the capacitor housing; the motor end transfer copper bar is arranged on one side of the capacitor housing; the AC copper bar comprises a cross-connected AC copper bar and a local AC copper bar, the local AC copper bar is used to connect the motor end transfer copper bar on the same side and the AC terminal of the power module; the cross-connected AC copper bar is used to connect the motor end transfer copper bar on the opposite side and the AC terminal of the power module; the upper end of the capacitor housing is open, and the opening is filled with potting material. The capacitor is potted, the bridging AC copper bar is arranged on the upper surface of the capacitor core and between the capacitor core and the potting material; the fixing seat comprises a positioning sleeve for wrapping the bridging AC copper bar, a positioning frame for connecting the two positioning sleeves, and a positioning column arranged on the positioning frame, the positioning column is arranged in the gap formed between the capacitor cores, and is used to fix the relative position between the capacitor core and the bridging AC copper bar; the AC current flowing out of the AC terminals of the power modules on both sides of the capacitor housing flows to the motor end transfer copper bar through the bridging AC copper bar and the main AC copper bar respectively.
[0006] Preferably, the motor-end transfer copper bar includes a first AC terminal of the motor for connecting to the power module on the same side, and a second AC terminal of the motor for connecting to the power module on the opposite side; the first AC terminal of the motor is inconsistent with the AC terminal of the power module on the same side, and the AC copper bar is bent to connect the first AC terminal of the motor and the AC terminal of the power module on the same side respectively; the two ends of the bridging AC copper bar are bent and laid on the top of the capacitor housing, and the upper surface of the second AC terminal of the motor is flush with the upper surface of the end of the bridging AC copper bar; and also includes a sub-copper bar, which is laid flat on the second AC terminal of the motor and the end of the bridging AC copper bar to electrically connect the bridging AC copper bar with the second AC terminal of the motor.
[0007] Preferably, a hollow structure is provided at the bending part of the bridging AC copper bar and the bending part of the actual AC copper bar.
[0008] Preferably, the positioning sleeve is slidably arranged on the positioning frame, and a locking piece is provided between the positioning sleeve and the positioning frame for locking the relative position between the positioning sleeve and the positioning frame.
[0009] Preferably, the positioning sleeve and the positioning frame are detachably connected, and the positioning frame can be connected to the positioning sleeves of different widths, and the positioning sleeves of different widths are used to wrap the jumper AC copper bars of different widths.
[0010] Preferably, the thickness of the AC copper busbar and the AC copper busbar is 0.5-1.0 mm.
[0011] Preferably, a cooling water channel is provided on a side of the power module facing away from the capacitor housing.
[0012] Preferably, a heat-conducting layer is provided between the side surface of the capacitor housing and the power module and between the cooling water channel and the power module, and the heat-conducting layer includes a heat-conducting glue.
[0013] Preferably, the AC terminal of the power module, the local AC copper busbar, the jumper AC copper busbar, the transfer copper busbar, and the motor-end transfer copper busbar are connected by laser welding.
[0014] The utility model also discloses a motor controller, comprising the above-mentioned double-sided water-cooled power module; the motor controller is connected to the motor, and the motor-end transfer copper bus outputs the AC current processed by the power module to the motor.
[0015] Compared with the prior art, the above technical solution has the following beneficial effects:
[0016] 1. The AC copper bar used for bridging is directly potted together with the capacitor, avoiding the situation where the AC copper bar used for bridging is set outside the capacitor and needs to be supported by the cantilever support member of the bridging on the top of the capacitor. Therefore, most of the volume of the AC copper bar can be fixed by potting, thereby enhancing the vibration strength of the power component as a whole; and because the cantilever support member of the bridging on the top of the capacitor is cancelled, the size of the AC copper bar fixing member is reduced;
[0017] 2. Since the cantilever support on the top of the capacitor is eliminated, the connection size between the AC copper busbar and the AC power terminals on both sides of the capacitor is easier to control, thereby reducing the design size accumulation and height tolerance, which is conducive to laser welding of the AC copper busbar. BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Figure 1 A three-dimensional diagram of a preferred embodiment of a double-sided water-cooled power module for a motor controller provided by the utility model;
[0019] Figure 2 An exploded view of a preferred embodiment of a double-sided water-cooled power module for a motor controller provided by the utility model;
[0020] Figure 3 A schematic diagram of the gap between capacitor cores used for positioning a fixing seat provided by the utility model;
[0021] Figure 4 A schematic structural diagram of a preferred embodiment of the fixing base and the cross-connecting AC copper busbar provided by the utility model;
[0022] Figure 5 A schematic structural diagram of a preferred embodiment of the motor end transfer copper bar and the plastic shell provided by the utility model.
[0023] Among them: 1-capacitor, 2-capacitor housing, 3-power module, 301-AC terminal of power module, 4-bridge AC copper busbar, 5-main AC copper busbar, 6-motor end transfer copper busbar, 7-plastic shell, 8-fixed seat, 801-positioning sleeve, 802-positioning frame, 803-positioning column, 9-cooling water channel, 10-sub copper busbar. DETAILED DESCRIPTION
[0024] The advantages of the present invention are further described below in conjunction with the accompanying drawings and specific embodiments.
[0025] 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.
[0026] 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.
[0027] 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".
[0028] In the description of the present invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present invention.
[0029] In the description of the present utility model, unless otherwise specified and limited, it should be noted that the terms "installation", "connection" and "connection" 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 of 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.
[0030] 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 they themselves have no specific meaning. Therefore, "module" and "component" can be used interchangeably.
[0031] See attached Figure 1-5 The utility model discloses a double-sided water-cooled power module for a motor controller. The power module generally includes a DC capacitor 1 and a power module 3. A DC current is input to the power module, and after being processed by the DC capacitor 1 and the power module 3, it flows out from the AC terminal 301 of the power module. At this time, the output AC current needs to be output to the motor to realize the control of the motor by the motor controller to which the power module belongs. Among them, the AC copper busbar is used to transfer the AC current output from the AC terminal 301 of the power module to the motor end transfer copper busbar 6.
[0032] The DC capacitor 1 of the power module of the utility model is arranged in the capacitor housing 2, and two three-phase power modules 3 are respectively arranged on both sides of the capacitor housing 2, and each three-phase power module 3 includes three power modules 3. The motor end transfer copper bar 6 is arranged on one side of the capacitor housing 2, and is used to connect with the AC terminal 301 of the power module on the same side and the AC terminal 301 of the power module on the opposite side.
[0033] The AC copper bar of the present invention includes a jumper AC copper bar 4 and a main AC copper bar 5. The main AC copper bar 5 is used to connect the motor end transfer copper bar 6 and the AC terminal 301 of the power module on the same side, and the jumper AC copper bar 4 is used to connect the motor end transfer copper bar 6 and the AC terminal 301 of the power module on the opposite side. It should be noted that "terminal" should be understood as the end of the connector. The "motor end transfer copper bar 6" and "AC terminal 301 of the power module" here are actually the same as the "AC copper bar", which are copper bars used to transmit current signals, and the "terminal" is the end of the copper bar.
[0034] After the capacitor 1 is installed inside the capacitor housing 2, it is usually necessary to potting with potting materials, that is, sealing. There are usually two potting forms. One is to open the upper part of the capacitor housing 2, and potting is performed on the upper part after the capacitor 1 is installed; the other is to open the side of the capacitor housing 2, and potting is performed on the side after the capacitor 1 is installed. The utility model is an opening at the upper end of the capacitor housing 2, and the opening is potted with potting materials, and the bridging AC copper bar 4 is potted together with the capacitor 1 inside the capacitor housing 2. Specifically, the upper surface of the capacitor 1 core is provided with a DC positive copper bar or a DC negative copper bar, and the bridging AC copper bar 4 is arranged on the upper part of the DC positive copper bar / DC negative copper bar, and is insulated by insulating paper, and then the capacitor 1, the DC positive copper bar / DC negative copper bar, and the bridging AC copper bar 4 are potted. Of course, the two ends of the bridging AC copper bar 4 need to be bent upward and then extend out of the capacitor housing 2 to connect with the AC terminal 301 of the power module on both sides and the motor end transfer copper bar 6.
[0035] Also includes a fixing seat 8, see attached Figure 3-4, used to fix the relative position between the bridging AC copper bar 4 and the capacitor 1, so as to ensure the position of the bridging AC copper bar 4. The fixing seat 8 is also arranged on the upper surface of the capacitor 1 core and arranged inside the capacitor housing 2, including a positioning sleeve 801 for enclosing the bridging AC copper bar 4, a positioning frame 802 for connecting the two positioning sleeves 801, and a positioning column 803 arranged on the positioning frame 802, and the positioning column 803 is stuck in the gap formed between the capacitor 1 cores, so as to fix the position of the positioning column 803 through the capacitor 1 core, and then fix the relative position between the capacitor 1 core and the bridging AC copper bar 4. Compared with the bridging AC copper bar 4 arranged outside the capacitor 1 filling cover in the prior art, the volume of the copper bar itself and the mold volume are reduced, and the fixing parts between the capacitor 1 filling cover and the capacitor housing 2 are also reduced, thereby reducing the cost.
[0036] Thus, the AC current flowing out of the AC terminals 301 of the power modules on both sides of the capacitor housing 2 flows to the motor end transfer copper bus 6 through the jumper AC copper bus 4 and the AC copper bus 5. Specifically, the AC currents output by different three-phase power modules 3 are output to the dual motors respectively, usually, one is output to the generator and the other is output to the drive motor.
[0037] See attached Figure 2 , 5 It should be noted that, for a power brick structure (the power module described in the utility model), it usually includes a "power module processing body" for the power module 3 (and its cooperation) to work, and a "transfer component" for outputting the AC current output by the "power module processing body" to the motor. The above-mentioned motor-end transfer copper bar 6 of the utility model belongs to the "transfer component" (carried by the injection molding support, and the injection molding support can be understood as the plastic shell 7). Usually, the "transfer component" needs to be designed differently according to the structure of the motor to match the AC three-phase input of the motor. Due to the transfer part, it is usually difficult to separate the "transfer component" and the "power module processing body" more cleanly in the prior art. The utility model can achieve this, thereby using the "power module processing body" as a universal part and the "transfer component" as a replaceable part. In the face of different motors, only the structure of the "transfer component" can be redesigned, and there is no need to make corresponding structural adjustments to the "power module processing body".
[0038] Preferably, the motor end transfer copper bar 6 includes a first AC terminal of the motor for connecting to the power module 3 on the same side, and a second AC terminal of the motor for connecting to the power module 3 on the opposite side. The height of the first AC terminal of the motor is inconsistent with the AC terminal 301 of the power module on the same side. After the AC copper bar 5 is bent, the first AC terminal of the motor is respectively connected to the AC terminal 301 of the power module on the same side, so as to electrically connect the first AC terminal of the motor with the AC terminal 301 of the power module on the same side. The two ends of the bridging AC copper bar 4 are bent and laid on the top of the capacitor housing 2. The upper surface of the second AC terminal of the motor is flush with the upper surface of the end of the bridging AC copper bar 4. The connection is achieved through a separate sub-copper bar 10. Specifically, the sub-copper bar 10 is laid flat on the second AC terminal of the motor and the end of the bridging AC copper bar 4, so as to electrically connect the bridging AC copper bar 4 with the second AC terminal of the motor.
[0039] In a preferred embodiment, the AC terminal 301 of the power module, the AC copper bar 5, the bridging AC copper bar 4, the transfer copper bar, and the motor end transfer copper bar 6 are connected by laser welding. Specifically, the bridging AC copper bar 4 and the AC terminal 301 of the power module, the bridging AC copper bar 4 and the transfer copper bar, the transfer copper bar and the motor end transfer copper bar 6, the motor end transfer copper bar 6 and the AC copper bar 5, and the AC copper bar 5 and the AC terminal 301 of the power module are all connected by laser welding.
[0040] Further preferably, a hollow structure is provided at the bending part of the bridging AC copper bus 4 and the bending part of the AC copper bus 5 to reduce the bending stress.
[0041] Preferably, for the structure of the fixing seat 8, the utility model provides two embodiments of the connection between the positioning sleeve 801 and the positioning frame 802. In the first embodiment, the positioning sleeve 801 is slidably arranged on the positioning frame 802, and a locking member is provided between the positioning sleeve 801 and the positioning frame 802 for locking the relative position between the positioning sleeve 801 and the positioning frame 802. By setting the positioning sleeve 801 as a sliding member, the position of the bridging AC copper bus 4 (relative to both ends) can be flexibly set. In the second embodiment, the positioning sleeve 801 and the positioning frame 802 are detachably connected, and the positioning frame 802 can be connected to the positioning sleeves 801 of different width sizes, and the positioning sleeves 801 of different width sizes are used to enclose the bridging AC copper bus 4 of different width sizes. The bridging AC copper bus 4 can be widened to be compatible with currents of different sizes. For example, the larger the required current, the wider the bridging AC copper bus 4.
[0042] Further preferably, the thickness of the connecting AC copper bar 5 and the bridging AC copper bar 4 is 0.5-1.0 mm. Compared with the prior art, the welding tool can apply less pressure to achieve welding. Moreover, after the thickness is reduced, the depth of the potting material used to pot the capacitor 1 can be reduced, thereby reducing the cost, and the potting compression rebound force is also reduced to facilitate potting.
[0043] Preferably, a cooling water channel 9 is provided on a side of the power module 3 facing away from the capacitor housing 2 , that is, cooling water is provided on the outermost side of the power module.
[0044] Furthermore, a heat conductive layer is provided between the side of the capacitor housing 2 and the power module 3, and between the cooling water channel 9 and the power module 3, so as to accelerate the heat flow between the capacitor housing 2, the power module 3 and the cooling water channel 9, and the heat conductive layer includes but is not limited to thermal conductive glue.
[0045] The utility model also discloses a motor controller, including the above-mentioned double-sided water-cooled power module. The motor controller is connected to the motor for controlling the motor. Specifically, the "power module processing body" is connected to the motor through the "adapter assembly", so that the motor end adapter copper bar 6 in the "adapter assembly" outputs the AC current processed by the power module 3 in the "power module processing body" to the motor, thereby realizing the control of the motor.
[0046] 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 double-sided water-cooled power module for a motor controller, characterized in that: include: A capacitor housing, in which a DC capacitor is arranged, and power modules are respectively arranged on both sides of the capacitor housing; a motor end transfer copper bus is arranged on one side of the capacitor housing; The AC copper bar comprises a bridging AC copper bar and a local AC copper bar, wherein the local AC copper bar is used to connect the motor end transfer copper bar and the AC terminal of the power module on the same side; the bridging AC copper bar is used to connect the motor end transfer copper bar and the AC terminal of the power module on the opposite side; the upper end of the capacitor housing is open, and the opening is potted with a potting material, and the bridging AC copper bar is arranged on the upper surface of the capacitor core of the DC capacitor and is arranged between the capacitor core and the potting material; A fixing seat, comprising a positioning sleeve for enclosing the bridging AC copper bar, a positioning frame for connecting the two positioning sleeves, and a positioning column arranged on the positioning frame, wherein the positioning column is arranged in the gap formed between the capacitor cores and is used to fix the relative position between the capacitor core and the bridging AC copper bar; The AC current flowing out of the AC terminals of the power modules on both sides of the capacitor housing flows to the motor end transfer copper bus through the jumper AC copper bus and the local AC copper bus respectively.
2. The double-sided water-cooled power module according to claim 1, characterized in that: The motor end transfer copper busbar includes a first AC terminal of the motor for connecting to the power module on the same side, and a second AC terminal of the motor for connecting to the power module on the opposite side; The height of the first AC terminal of the motor is inconsistent with that of the AC terminal of the power module on the same side. After the AC copper bar is bent, it is respectively connected to the first AC terminal of the motor and the AC terminal of the power module on the same side; The two ends of the bridging AC copper bar are bent and placed on the top of the capacitor housing, and the upper surface of the second AC terminal of the motor is flush with the upper surface of the end of the bridging AC copper bar; and a sub-copper bar is also included, which is laid flat on the second AC terminal of the motor and the end of the bridging AC copper bar to electrically connect the bridging AC copper bar with the second AC terminal of the motor.
3. The double-sided water-cooled power module according to claim 2, characterized in that: The bending part of the bridging AC copper bar and the bending part of the actual AC copper bar are provided with a hollow structure.
4. The double-sided water-cooled power module according to claim 1, characterized in that: The positioning sleeve is slidably arranged on the positioning frame, and a locking piece is arranged between the positioning sleeve and the positioning frame for locking the relative position between the positioning sleeve and the positioning frame.
5. The double-sided water-cooled power module according to claim 1 or 4, characterized in that: The positioning sleeve is detachably connected to the positioning frame, and the positioning frame can be connected to the positioning sleeves of different widths. The positioning sleeves of different widths are used to enclose the jumper AC copper bars of different widths.
6. The double-sided water-cooled power module according to claim 1, characterized in that: The thickness of the AC copper bar and the AC copper bar is 0.5-1.0 mm.
7. The double-sided water-cooled power module according to claim 1, characterized in that: A cooling water channel is provided on a side of the power module facing away from the capacitor housing.
8. The double-sided water-cooled power module according to claim 7, characterized in that: A heat-conducting layer is provided between the side surface of the capacitor housing and the power module, and between the cooling water channel and the power module, and the heat-conducting layer includes heat-conducting glue.
9. The double-sided water-cooled power module according to claim 1, characterized in that: The AC terminal of the power module, the local AC copper bar, the cross-connected AC copper bar, the transfer copper bar, and the motor-end transfer copper bar are connected by laser welding.
10. A motor controller, characterized in that: It comprises the double-sided water-cooled power module as described in any one of claims 1 to 9 above; the motor controller is connected to the motor, and the motor-end adapter copper bus outputs the AC current processed by the power module to the motor.