Motor Controllers and Automotive

Abstract

The utility model discloses a motor controller and a car, and relates to the field of automobile technology, wherein the motor controller comprises a base shell, a capacitor core and an IGBT module, one end of the base shell is connected with a DC input terminal, and the other end is integrally injection-molded with an AC output terminal; the capacitor core is placed in the base shell, and the capacitor core is connected to the DC input terminal; the IGBT module is connected to the base shell, and the IGBT module and the capacitor core are arranged side by side along the width direction of the base shell, and are connected between the capacitor core and the AC output terminal; the technical solution provided by the utility model can improve the power density of the motor controller.

Description

Technical Field

[0001] The utility model relates to the technical field of automobiles, in particular to a motor controller and an automobile. Background Art

[0002] In new energy vehicles, the motor controller can convert the direct current provided by the power battery into alternating current, providing power to the vehicle's drive motor to drive the vehicle.

[0003] A common motor controller is composed of multiple single-function parts connected by simple bolts. That is, the capacitor structure, busbar terminal block, IGBT water channel and other parts are installed on the cast aluminum shell by bolts, and the capacitor structure and the busbar terminal block are connected by bolts. As a result, due to the large number of parts, the overall weight is heavy and the power density is low. Utility Model Content

[0004] The main purpose of the utility model is to provide a motor controller and a car, aiming to improve the power density of the motor controller.

[0005] To achieve the above-mentioned purpose, the motor controller proposed by the utility model comprises:

[0006] A base shell, one end of which is connected to a DC input terminal, and the other end of which is integrally molded with an AC output terminal;

[0007] A capacitor core is disposed in the base shell, and the capacitor core is connected to the DC input terminal; and

[0008] An IGBT module is connected to the base shell. The IGBT module and the capacitor core are arranged side by side along the width direction of the base shell and are connected between the capacitor core and the AC output terminal.

[0009] In one embodiment, the base shell includes a first shell portion and a second shell portion, the capacitor core is fixed in the first shell portion, one end of the DC input end is connected to the first shell portion, and the other end extends in a direction away from the first shell portion, and the second shell portion is connected to the IGBT module and fixes the AC output end.

[0010] In one implementation, the DC input terminal is fixed to the first shell portion by epoxy potting.

[0011] In one embodiment, the IGBT module is connected to the second housing via a cooling module.

[0012] In one embodiment, the IGBT module and the cooling module are welded;

[0013] And / or, a plurality of IGBT modules are provided and arranged along the length direction of the cooling module.

[0014] In one embodiment, the cooling module is embedded in the second shell;

[0015] And / or, the cooling module is connected to the base shell by bolts.

[0016] In one embodiment, the cooling module includes an upper cover, a lower box and heat-conducting fins, the upper cover, the heat-conducting fins and the lower box are connected to form a cooling water channel, and the lower box is connected to the second shell.

[0017] In one embodiment, the upper cover and the lower box are both forged aluminum parts or forged copper parts;

[0018] And / or, the upper cover, the heat conducting fins and the lower box are connected by brazing.

[0019] In one embodiment, the base shell is made of plastic.

[0020] In one embodiment, the capacitor output pin of the capacitor core and the DC terminal of the IGBT module, and the AC terminal of the IGBT module and the AC output end are connected by laser welding.

[0021] In one embodiment, the motor controller further includes a circuit board, which is located above the IGBT module and can shield the capacitor core.

[0022] The utility model also provides a car, which comprises the motor controller as described above.

[0023] In the technical solution of the utility model, an AC output terminal is integrally injection-molded on the base shell, and also replaces the original shell of the film capacitor, which helps to reduce the overall weight of the motor controller, reduces costs, and further improves the power density and integration level of the motor controller.

[0024] The base shell serves as the mounting base for the capacitor core, IGBT module, DC access terminal and AC output terminal, so that they are arranged horizontally in the width direction of the base shell, reducing the space occupied by the motor controller in the thickness direction of the capacitor core, further improving the integration level of the motor controller, and at the same time, simplifying the assembly process between the various parts, which helps to improve the assembly efficiency of the motor controller. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] 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 or the description of the prior art 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 the structures shown in these drawings without paying creative work.

[0026] Figure 1 An exploded diagram of an embodiment of a motor controller provided by the utility model;

[0027] Figure 2 for Figure 1 Assembly drawing of the middle base shell, capacitor core, DC input terminal and AC output terminal;

[0028] Figure 3 for Figure 1 Exploded view of the cooling module.

[0029] Description of Figure Numbers:

[0030] 10. base shell; 11. first shell portion; 12. second shell portion; 13. DC input terminal; 14. AC output terminal;

[0031] 20. Capacitor core; 21. Capacitor output pin;

[0032] 30. IGBT module; 31. DC terminal; 32. AC terminal;

[0033] 40. Cooling module; 41. Upper cover; 42. Lower box; 43. Heat conducting fins; 44. Connecting column;

[0034] 50. Circuit board.

[0035] The realization of the purpose, functional features and advantages of the utility model will be further explained in conjunction with embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION

[0036] 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 of 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.

[0037] It should be noted that if the embodiments of the present invention involve directional indications (such as up, down, left, right, front, back...), the directional indications are only used to explain the relative position relationship, movement status, etc. between the components in a certain specific posture. If the specific posture changes, the directional indications will also change accordingly.

[0038] In addition, if there are descriptions involving "first", "second", etc. in the embodiments of the utility model, the descriptions of "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Therefore, the features limited to "first" and "second" may explicitly or implicitly include at least one of the features. In addition, if "and / or" or "and / or" appears in the full text, its meaning includes three parallel solutions. Taking "A and / or B" as an example, it includes solution A, solution B, or solutions that satisfy both A and B. In addition, the technical solutions between the various embodiments can be combined with each other, but it must be based on the ability of ordinary technicians in this field to implement. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such combination of technical solutions does not exist and is not within the scope of protection required by the utility model.

[0039] Common motor controllers are composed of multiple single-function parts connected by simple bolts. That is, the capacitor structure, busbar terminal block, IGBT water channel and other parts are installed on the cast aluminum housing by bolts, and the capacitor structure and the busbar terminal block (terminal block) are connected by bolts. As a result, due to the large number of parts, the overall weight is heavy and the power density is low. It is difficult to pre-install the parts, which also leads to slow production cycle and affects production efficiency.

[0040] In order to solve this technical problem, the utility model proposes a motor controller to improve the power density of the motor controller and, at the same time, enhance the integration level of the motor controller.

[0041] See also Figures 1 to 3 In one embodiment of the utility model, the motor controller includes a base shell 10, a capacitor core 20 and an IGBT module 30. One end of the base shell 10 is connected to a DC input terminal 13, and the other end is integrally molded with an AC output terminal 14; the capacitor core 20 is placed in the base shell 10, and the capacitor core 20 is connected to the DC input terminal 13; the IGBT module 30 is connected to the base shell 10, and the IGBT module 30 and the capacitor core 20 are arranged side by side along the width direction of the base shell 10, and are connected between the capacitor core 20 and the AC output terminal 14.

[0042] In the technical solution of the utility model, the AC output terminal 14 is integrally injection-molded on the base shell 10, and also replaces the original shell of the film capacitor, which helps to reduce the overall weight of the motor controller, reduce costs, and further improve the power density and integration level of the motor controller.

[0043] The base shell 10 serves as a mounting base for the capacitor core 20, the IGBT module 30, the DC input terminal and the AC output terminal 14, so that they are arranged horizontally in the width direction of the base shell 10, reducing the space occupied by the motor controller in the thickness direction of the capacitor core 20, further improving the integration level of the motor controller, and at the same time, simplifying the assembly process between the various parts, which helps to improve the assembly efficiency of the motor controller.

[0044] See also Figure 2 In an embodiment of the utility model, the base shell 10 includes a first shell portion 11 and a second shell portion 12, the capacitor core 20 is fixed in the first shell portion 11, one end of the DC input terminal 13 is connected to the first shell portion 11, and the other end extends in a direction away from the first shell portion 11, the second shell portion 12 is connected to the IGBT module 30, and the AC output terminal 14 is fixed, wherein the first shell portion 11, the second shell portion 12 and the AC output terminal 14 are arranged along the width direction of the base shell 10 (the width direction of the capacitor core 20), and are pre-fixed as a whole, compared with completing the assembly between the capacitor core 20 and the IGBT module 30, the AC output terminal 14 and the base shell 10 by connecting parts such as bolts, the assembly steps are effectively simplified, and the overall weight is also reduced; compared with the longitudinal arrangement of the thin film capacitor and the IGBT module 30, the lateral space under the vehicle can be fully utilized to arrange the motor controller, so as to increase the riding space in the vehicle and improve the riding comfort.

[0045] In the width direction of the base shell 10, the first shell portion 11 is connected with a DC input terminal 13 and a capacitor output pin 21 extending in opposite directions, so that the capacitor output pin 21 extends out of the first shell portion 11 and extends toward the IGBT module 30, which facilitates the connection of the capacitor output pin 21 with the DC terminal 31 of the IGBT module 30, and completes the output of DC power compactly and reliably. The capacitor core 20 is a thin film capacitor core.

[0046] The AC output terminal 14 is arranged on the side of the second shell portion 12 away from the first shell portion 11 , which fully utilizes the assembly space of the base shell 10 in its width direction, facilitates one-piece injection molding, improves integration, and further improves the power density of the motor controller, and also facilitates subsequent wiring operations through the AC output terminal 14 .

[0047] There are many ways to fix the capacitor core 20 and the first shell 11. In the embodiment of the utility model, the first shell 11 is provided with a first installation cavity for accommodating the capacitor core 20, that is, the capacitor core 20 is embedded in the first installation cavity and protected by the first shell 11, and the capacitor core 20 can be fixed in the base shell 10 by injection molding epoxy glue. There are many ways to fix the IGBT module 30 and the second shell 12, including but not limited to bolt connection, embedding, and clamping.

[0048] Furthermore, in an embodiment of the utility model, the DC input terminal 13 is fixed to the first shell portion 11 by epoxy potting, that is, the capacitor core 20 and the DC input terminal 13 can be potted together, which optimizes the assembly steps, improves the assembly efficiency, and can increase the heat exchange area.

[0049] Compared with the IGBT water channel multi-purpose cast aluminum shell and the IGBT module 30's own copper base plate formed by bolt pressurized sealing ring, it is easy to cause coolant leakage due to factors such as processing technology, or affect the power ductility of the motor controller. In an embodiment of the utility model, the IGBT module 30 is connected to the second shell 12 through a cooling module 40. It can be understood that the IGBT module 30 and the cooling module 40 are relatively independent and do not interfere with each other. On the one hand, it helps to reduce the risk of coolant leakage and reduce or eliminate high-voltage safety problems. On the other hand, it improves the low power ductility caused by factors such as shared structure.

[0050] In addition, since the cooling module 40 is arranged between the second shell 12 and the IGBT module 30, the heat dissipation requirements of the IGBT module 30 can be met. Also, since there is a large effective contact area between the first shell 11 and the second shell 12, the capacitor core 20 can be cooled to a certain extent.

[0051] Specifically, in the embodiment of the utility model, the IGBT module 30 and the cooling module 40 are welded; the IGBT module 30 and the cooling module 40 are fixed as a whole in advance, and then, the IGBT module 30 or the cooling module 40 is connected to the second shell 12, so that the IGBT module 30 and the cooling module 40 can be assembled on the base shell 10. More specifically, the IGBT module 30 is sintered and welded to the cooling module 40. However, in other embodiments, the IGBT module 30 and the cooling module 40 are bonded or spliced.

[0052] According to the power requirement of the motor controller, in the embodiment of the present utility model, a plurality of IGBT modules 30 are provided and arranged along the length direction of the cooling module 40, wherein the specific number of IGBT modules 30 can be increased or decreased according to the power requirement. Each IGBT module 30 is fixed to the cooling module 40 by welding, and its DC terminal 31 extends toward the capacitor output pin 21, and the AC terminal 32 extends toward the AC output terminal 14.

[0053] There are many ways to fix the cooling module 40 and the second shell 12. In an embodiment of the present invention, the cooling module 40 is embedded in the second shell 12, that is, a second installation cavity for accommodating the cooling module 40 is formed on the second shell 12 to increase the contact area between the cooling module 40 and the second shell 12, and at the same time fix the cooling module 40 to the base shell 10, thereby fixing the IGBT module 30 on the base shell 10, and facilitating the electrical connection between the IGBT module 30 and the capacitor core 20.

[0054] Furthermore, in an embodiment of the present invention, the cooling module 40 is connected to the base shell 10 by bolts. The bolts are provided to enhance the connection strength between the cooling module 40 and the IGBT module 30 and the base shell 10 .

[0055] See also Figure 3 In an embodiment of the utility model, the cooling module 40 includes an upper cover 41, a lower box 42 and a heat-conducting fin 43, the upper cover 41, the heat-conducting fin 43 and the lower box 42 are connected to form a cooling water channel, the lower box 42 is connected to the second shell 12, wherein a connecting column 44 is provided on the peripheral side of the lower box 42, and a first connecting hole for a bolt to extend therein is provided on the connecting column 44, and the second shell 12 is provided with a second connecting hole docking with the first connecting hole, and then the first connecting hole and the second connecting hole are connected in series by bolts to complete the connection between the lower box 42 and the second shell 12.

[0056] Specifically, in an embodiment of the utility model, the upper cover 41, the heat-conducting fins 43 and the lower box 42 are connected by brazing to form a cooling water channel, wherein the lower box 42 is provided with an inlet and an outlet connected to the cooling water channel, and the inlet and the outlet both pass through the second shell portion 12, so as to facilitate the connection of the overall cooling system, introduce coolant and cool the heat dissipation IGBT module 30.

[0057] More specifically, in the embodiment of the utility model, the upper cover 41 and the lower box 42 are both forged aluminum or copper; compared with the shrinkage and shrinkage holes caused by the cast aluminum process, which lead to coolant leakage, when the upper cover 41 and the lower box 42 are both forged aluminum or copper, the risk of coolant leakage in the cooling module 40 is reliably reduced, which helps to solve the high-voltage safety problem and improve the reliability of the cooling module 40. The heat-conducting fins 43 are stamped from aluminum plates or copper plates.

[0058] Optionally, in an embodiment of the utility model, the base shell 10 is made of plastic material; compared with the base shell 10 made of cast aluminum material, the base shell 10 made of plastic material can reduce the overall weight and cost, while improving the power density of the motor controller; it can also reduce the demand for high-voltage insulation space of the motor controller.

[0059] There are many ways to electrically connect the IGBT module 30 and the capacitor core 20. In the embodiment of the present utility model, the capacitor output pin 21 of the capacitor core 20 and the DC terminal 31 of the IGBT module 30, and the AC terminal 32 of the IGBT module 30 and the AC output terminal 14 are connected by laser welding, that is, Figures 1 to 2 As shown, on the base shell 10, the capacitor output pin 21 is directly connected to the DC terminal 31 of the IGBT module 30 by laser welding, without adding additional bolts and through holes to complete the electrical connection between the IGBT module 30 and the capacitor core 20. Similarly, the AC terminal 32 of the IGBT module 30 is connected to the AC output terminal 14 by laser welding to complete the electrical connection between the IGBT module 30 and the AC output terminal 14, thereby ensuring the output of AC power and reducing the number of bolts. In this way, the electrical connection structure is simpler, which helps to improve the overall space utilization; the assembly is also more convenient, which helps to improve the production efficiency of the motor controller.

[0060] See also Figure 1 In an embodiment of the utility model, the motor controller further comprises a circuit board, which is located above the IGBT module 30 and can shield the capacitor core 20, wherein the pins of the IGBT module 30 extend upward and are fixed to the circuit board by selective welding. In addition, due to the large area of ​​the circuit board, it extends to the top of the first shell 11 to a certain extent and shields the capacitor core 20.

[0061] The utility model also proposes a car, which includes a motor controller. The specific structure of the motor controller refers to the above embodiments. Since the car adopts all the technical solutions of all the above embodiments, it has at least all the beneficial effects brought by the technical solutions of the above embodiments, which will not be described one by one here.

[0062] The above description is only an exemplary embodiment of the present invention, and does not limit the patent scope of the present invention. All equivalent structural changes made by using the contents of the present invention specification and drawings under the technical concept of the present invention, or directly / indirectly applied in other related technical fields are included in the patent protection scope of the present invention.

Claims

1. A motor controller, characterized in that: include: A base shell, one end of which is connected to a DC input terminal, and the other end of which is integrally molded with an AC output terminal; A capacitor core is placed in the base shell, and the capacitor core is connected to the DC input terminal; as well as An IGBT module is connected to the base shell. The IGBT module and the capacitor core are arranged side by side along the width direction of the base shell and are connected between the capacitor core and the AC output terminal.

2. The motor controller according to claim 1, characterized in that: The base shell includes a first shell portion and a second shell portion, the capacitor core is fixed in the first shell portion, one end of the DC input end is connected to the first shell portion, and the other end extends in a direction away from the first shell portion, the second shell portion is connected to the IGBT module and fixes the AC output end.

3. The motor controller according to claim 2, characterized in that: The DC input terminal is fixed on the first shell portion by epoxy glue potting.

4. The motor controller according to claim 2, characterized in that: The IGBT module is connected to the second shell via a cooling module.

5. The motor controller according to claim 4, characterized in that: The IGBT module and the cooling module are welded; And / or, a plurality of IGBT modules are provided and arranged along the length direction of the cooling module.

6. The motor controller according to claim 4, characterized in that: The cooling module is embedded in the second shell; And / or, the cooling module is connected to the base shell by bolts.

7. The motor controller according to claim 4, characterized in that: The cooling module includes an upper cover, a lower box and heat-conducting fins. The upper cover, the heat-conducting fins and the lower box are connected to form a cooling water channel. The lower box is connected to the second shell.

8. The motor controller according to claim 7, characterized in that: The upper cover and the lower box are both forged aluminum parts or forged copper parts; And / or, the upper cover, the heat conducting fins and the lower box are connected by brazing.

9. The motor controller according to claim 1, characterized in that: The base shell is made of plastic; And / or, the capacitor output pin of the capacitor core and the DC terminal of the IGBT module, and the AC terminal of the IGBT module and the AC output end are connected by laser welding.

10. The motor controller according to claim 1, characterized in that: The motor controller further comprises a circuit board, which is located above the IGBT module and can shield the capacitor core.

11. A car, characterized in that: Comprising a motor controller as claimed in any one of claims 1 to 10.

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