Integrated motor controller and new energy vehicles

Abstract

The utility model discloses an integrated motor controller and a new energy vehicle, and is in the technical field of designing new energy vehicles, wherein the motor controller includes a housing and a power module, one side of the housing has a housing cavity, and a filter component, a high-voltage connector, a boost inductor, a circuit board, and a copper busbar component are partially arranged in the housing cavity; the power module is arranged in the housing cavity, and the power module has a heat sink; and a plurality of boost power devices and a plurality of rectifier power devices, and the plurality of boost power devices and the plurality of rectifier power devices are arranged on both sides of the heat sink. The solution of using a common board for boost power devices and rectifier power devices has high integration, improves internal space utilization, and is conducive to product miniaturization. Therefore, the utility model aims to solve the disadvantage of excessive volume by increasing the space utilization of the motor controller.

Description

Technical Field

[0001] The utility model relates to the technical field of new energy vehicles, in particular to an integrated motor controller and a new energy vehicle. Background Art

[0002] Oil shortage, environmental pollution and climate warming are common challenges facing the global automotive industry. Governments of various countries have successively released new energy vehicle development strategies and national plans, and increased support for complete vehicles. As the breakthrough of new energy vehicle technology bottlenecks is expected to accelerate, the motor controllers of new energy vehicles are driven to develop towards high performance, high reliability, low cost, lightweight and miniaturization.

[0003] The extended-range generator controller is mainly used to control the output voltage and frequency of the generator to adapt to the load requirements. This controller requires not only logic control and signal processing, but may also include multiple independent components such as a boost system, a rectifier system, and multiple circuit boards. In traditional new energy vehicles, these different functional modules or functional components are dispersed in the front box or rear box, and each of them occupies a certain space, which leads to the complex structure and excessive size of traditional new energy vehicles. The internal space utilization rate is low, which may ultimately lead to low mechanical strength and safety of the entire vehicle. Utility Model Content

[0004] The utility model aims to increase the space utilization of the front box / rear box of the new energy vehicle by integrating various independent components, so as to solve the disadvantage of excessive volume.

[0005] In order to solve the above problems, the utility model proposes an integrated motor controller comprising:

[0006] A box body, wherein one side of the box body has a receiving cavity;

[0007] a power module, disposed in the accommodating cavity, wherein the power module has a heat dissipation plate; and

[0008] A plurality of boost power devices and a plurality of rectifier power devices are respectively arranged on two sides of the heat sink.

[0009] In one embodiment, the power module further comprises:

[0010] A plastic overmolding assembly, wherein the power module is covered by the plastic overmolding assembly, a copper busbar assembly is arranged inside the plastic overmolding assembly, the copper busbar assembly is electrically connected to a plurality of boost power devices and a plurality of rectifier power devices on the power module, and a plurality of pairs of connecting copper busbars are extended from the side of the plastic overmolding assembly for electrical connection between the power module and other electrical components.

[0011] In one embodiment, a thin film capacitor is further included, which is arranged in the accommodating cavity. The thin film capacitor has a shell, a boost capacitor and at least one rectifier bus capacitor arranged in the shell.

[0012] In one embodiment, the thin film capacitor also includes a positive copper bar, a negative copper bar and a positive boost copper bar, the negative copper bar is electrically connected to the negative end of the boost capacitor and the at least one rectifier bus capacitor, the positive copper bar is electrically connected to the positive end of the at least one rectifier bus capacitor, and the positive boost copper bar is electrically connected to the positive end of the boost capacitor.

[0013] In one embodiment, the negative copper bar is arranged at the bottom of the shell, and a plurality of connecting plates are arranged perpendicularly to the negative copper bar at the edge of the negative copper bar, and the plurality of connecting plates are attached to the inner wall of the shell, and each connecting plate is provided with a negative sub-connecting plate perpendicular thereto, and the negative sub-connecting plate is arranged outside the shell;

[0014] The positive electrode copper busbar is provided with a positive electrode connecting plate corresponding to the negative electrode connecting plate, and each of the negative electrode connecting plates and each of the positive electrode connecting plates form an electrical connection port.

[0015] In one embodiment, the film capacitor is electrically connected to the power module, and a plurality of pairs of the connecting copper bars are electrically connected to the electrical connection ports correspondingly.

[0016] In one embodiment, a circuit board is further included, which is arranged in the accommodating cavity, the circuit board integrates a control circuit and a power circuit, the power module has a plurality of pins, and the circuit board has a plurality of connecting parts for welding with the pins.

[0017] In one embodiment, the motor controller further includes a boost inductor disposed in the accommodating cavity, an output end of the boost inductor is electrically connected to the film capacitor, and an input end of the boost inductor is electrically connected to the power module.

[0018] The utility model also discloses a new energy vehicle, which comprises a motor and the above-mentioned integrated motor controller.

[0019] In one embodiment, the integrated motor control has a first water channel that runs through the accommodating cavity, and the motor has a second water channel. The size of the first water channel is adapted to the size of the second water channel, and the first water channel and the second water channel are connected to form a common water channel.

[0020] It can be seen that the utility model discloses an integrated motor controller, which effectively integrates multiple functional modules, reduces the volume of the motor controller, is easy to install and arrange inside the vehicle, and maintains good mechanical strength and safety. The integrated motor controller mainly includes a box, a film capacitor and a power module. A shell is provided inside the film capacitor, and a boost capacitor and at least one rectifier bus capacitor are arranged in order in the shell, and electrical connection is achieved through a positive copper bus, a negative copper bus and a positive boost copper bus, wherein a positive sub-connection plate and a negative sub-connection plate are specially designed, and the connecting copper bus of the power module is matched to form an efficient and compact electrical connection structure. The power module integrates a plurality of boost power devices and a plurality of rectifier power devices and a heat sink, and all circuit components are arranged on both sides of a plane of the heat sink, and are electrically connected to the film capacitor through the connecting copper bus. At the same time, the power module also takes into account the heat dissipation requirements and adopts a heat sink. The entire motor controller is rationally designed and fully utilizes the internal space. Not only are the filter components, high-voltage connectors, boost inductors, circuit boards (including control boards and power boards) and copper busbar components rationally arranged in the accommodating cavity, but the capacitors and power modules are also efficiently integrated, reducing the overall volume and complexity of the controller.

[0021] In addition, the utility model also proposes a new energy vehicle, in which the above-mentioned integrated motor controller has been applied, which adopts a shared water channel design for the motor and the electronic control, further improving the integration and efficiency of the entire power system.

[0022] In general, the following beneficial effects were achieved:

[0023] 1. Multiple boost power devices and multiple rectifier power devices share a water cooling plate to improve internal space utilization.

[0024] 2. The film capacitor integrates the boost capacitor and at least one rectifier bus capacitor, and the design is integrated to improve the internal space utilization of the electronic control.

[0025] 3. The electronic control integrated boost module makes the output voltage have better stability.

[0026] 4. The control board and the power board share the same board, with high integration.

[0027] 5. The electronic control and motor share the same water channel, with high integration. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] 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.

[0029] Figure 1 It is an exploded schematic diagram of the integrated motor controller in the utility model;

[0030] Figure 2 It is a schematic diagram of the power module and the plastic package component in the utility model;

[0031] Figure 3 It is an exploded schematic diagram of the plastic-coated component in the utility model;

[0032] Figure 4 It is a schematic diagram of the film capacitor in the utility model.

[0033] Description of Figure Numbers:

[0034] Label name Label name Motor Controller 1 Pinout 250 EMC filter components 10 Film capacitors 300 Three-phase copper busbar assembly 20 case 310 Terminal input harness 30 Support table 311 Hall chip 40 Boost capacitor 320 Cabinet 100 Rectifier bus capacitor 330 Accommodation cavity 110 Positive copper bus 340 Power Module 200 Positive terminal connection plate 341 Heat sink 210 Positive boost copper busbar 350 Boost Power Devices 220 Positive boost sub-connector plate 351 Rectifier power devices 230 Negative copper bus 360 Plastic package components 240 Negative terminal connection plate 361 The first copper busbar pair 241 First electrical connection port 370 The second copper busbar pair 242 Second electrical connection port 380 The third copper busbar pair 243 Circuit Board 400 Three-phase copper busbar 244 Connection 410 Hall chip limit hole 245 Boost Inductor 500 Hole 246 First Waterway 600 Magnetic ring 247

[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 all directional indications in the embodiments of the present invention (such as up, down, left, right, front, back...) are only used to explain the relative position relationship, movement status, etc. between the components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0038] In addition, the descriptions of "first", "second", etc. in the present utility model are only used for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In addition, the technical solutions between the various embodiments can be combined with each other, but they must be based on the ability of ordinary technicians in this field to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by the present utility model.

[0039] The extended-range generator controller is mainly used to control the output voltage and frequency of the generator to adapt to the load requirements. This controller requires not only logic control and signal processing, but may also include multiple independent components such as a boost system, a rectifier system, and multiple circuit boards. In traditional new energy vehicles, these different functional modules or functional components are dispersed in the front box or rear box, and each of them occupies a certain space, which leads to the complex structure and excessive size of traditional new energy vehicles. The internal space utilization rate is low, which may ultimately lead to low mechanical strength and safety of the entire vehicle.

[0040] Combined with reference Figure 1-Figure 3 In order to solve the above problems, the utility model proposes an integrated motor controller 1, which includes a box body 100, a power module 200, a plurality of boost power devices 220 and a plurality of rectifier power devices 230. One side of the box body 100 has a accommodating cavity 110, and the power module 200 is arranged in the accommodating cavity 110. The power module 200 has a heat dissipation plate 210. The plurality of boost power devices 220 and the plurality of rectifier power devices 230 of the motor controller 1 are arranged on both sides of a plane of the heat dissipation plate 210.

[0041] In this embodiment, there are five boost power devices 220 and five rectifier power devices 230, which are arranged in two rows on the heat sink 210, and each power device is provided with a plurality of pins 250 for connecting to the circuit board 400. By arranging the power devices in two rows, the space on the heat sink 210 can be more effectively utilized, and the mutual interference between the power devices can be reduced, which is also beneficial to the design and manufacture of the heat sink 210. This layout helps to reduce the overall size of the motor controller 1 and improve the space utilization of the whole vehicle.

[0042] In some exemplary new energy vehicle motor controllers, a decentralized design is usually adopted, in which each functional module and component (such as power module, boost power device, rectifier power device, etc.) is independently arranged. These independent components need to be interconnected through wiring harnesses and connectors to achieve the transmission and control of electric energy. The decentralized design causes each component to occupy more space, which is not conducive to the lightweight and space optimization of new energy vehicles. Therefore, this embodiment achieves a high degree of integration by placing multiple boost power devices 220 and multiple rectifier power devices 230 on both sides of a plane of the heat sink 210 and placing them in a box 100, which significantly improves the space utilization of the whole vehicle.

[0043] The box 100 is made of a material with strong heat dissipation capability, which can be aluminum or copper. It should be noted that aluminum has poor corrosion resistance and requires additional coating or treatment for protection to enhance the heat dissipation function of the motor controller 1. The housing cavity 110 of the box 100 is also provided with an EMC filter assembly 10, a high-voltage connector, a boost inductor 500, a terminal input harness 30, a three-phase copper busbar assembly 20, a power module 200, a film capacitor 300, a circuit board 400, etc. Other devices can be added according to the needs of the vehicle.

[0044] In addition, the heat sink 210 has two locating pins, through which the heat sink 210 can be limited in the box 100, and then fixedly connected to the box 100 by four bolts. Such a design can prevent its shaking and negatively affect the structural strength of the motor controller 1. The heat sink 210 is a water-cooled plate, and the heat sink 210 is provided with a heat dissipation PIN needle, which can effectively speed up the heat dissipation efficiency. The module is fixed to the box 100 by screws, and the water-cooled plate and the box 100 are sealed by a sealing ring. As an efficient heat dissipation method, the water-cooled plate can quickly absorb and conduct heat, and further increase the heat dissipation surface area through the heat dissipation PIN needle, thereby effectively improving the heat dissipation efficiency, improving the stability of the motor controller 1 during high-load operation, and extending its service life.

[0045] Therefore, this embodiment adopts a water-cooled plate solution for the boost power device 220 and the rectifier power device 230, which improves the heat dissipation capacity of the motor controller 1, and has a high degree of integration, improves the internal space utilization, is conducive to product miniaturization and lightweight, reduces material types, and simplifies installation steps.

[0046] In this embodiment, the power module 200 further comprises: a plastic package component 240, the plastic package component 240 covers the power module 200, a copper busbar component is arranged inside the plastic package component 240, the copper busbar component is electrically connected to a plurality of boost power devices 220 and a plurality of rectifier power devices 230 on the power module 200, and the copper busbar component extends from the side of the plastic package component 240 with a plurality of pairs of connecting copper busbars for electrical connection of the power module and other electrical components. The plastic package component 240 covers the power module 200 and is electrically connected to a plurality of boost power devices 220 and a plurality of rectifier power devices 230 on the power module 200, thus realizing a modular design. This design enables the power module 200 to have a high degree of integration, facilitates installation and maintenance, and reduces the number and complexity of external connection lines.

[0047] Combined with reference Figure 1 and Figure 3The interior of the overmolded component 240 is provided with an interactive copper busbar assembly, and is effectively electrically connected to the multiple boost power devices 220 and the multiple rectifier power devices 230 on the power module 200. The side of the overmolded component 240 has a mounting hole. After the above copper busbar assembly is arranged, each port of the copper busbar assembly extends from the mounting hole on the side of the overmolded component 240 to form a corresponding connecting copper busbar. The multiple pairs of connecting copper busbars include a first copper busbar pair 241, a second copper busbar pair 242, a third copper busbar pair 243 and a three-phase end copper busbar 244, which are used to electrically connect with other devices.

[0048] The three-phase copper bar 244 is sleeved with a magnetic ring 247. This embodiment also includes a three-phase copper bar assembly 20. The three-phase copper bar assembly 20 is connected to the three-phase copper bar 244 of the power module 200 through three bolts. At the same time, the three-phase copper bar assembly 20 is limited by two positioning pins and fixed to the box 100 through four bolts. The magnetic ring 247 can absorb and reflect electromagnetic waves, thereby reducing the impact of electromagnetic radiation on external devices. When sleeved on the three-phase copper bar 244, electromagnetic interference can be effectively suppressed.

[0049] In addition, this embodiment further includes a Hall chip 40 , and the overmolded component 240 includes two Hall chip limiting holes 245 for limiting the Hall chip 40 .

[0050] In this embodiment, combined with reference Figure 1 and Figure 4 The motor controller 1 also includes a film capacitor 300, which is also a core integrated component and is arranged in the accommodating cavity 110. The film capacitor 300 has a housing 310 and a boost capacitor 320 and at least one rectifier bus capacitor 330 arranged in the housing 310. The boost capacitor 320 and the rectifier bus capacitor 330 play a key role in the motor controller 1. They are responsible for increasing the voltage to meet the motor output requirements and filtering the current ripple to ensure the quality of power, which is crucial for the normal operation of the motor controller 1. Therefore, the priority integration of these capacitors can ensure the realization of basic functions.

[0051] The film capacitor 300 is arranged in the accommodating cavity 110 as an integrated component, integrating a boost capacitor 320 and at least one rectifier bus capacitor 330, thereby improving the integration of the motor controller 1. The compact design helps to save space inside the motor controller 1 and improve space utilization, thereby reducing the volume and weight of the entire controller. In contrast, in the design of some exemplary motor controllers, the boost capacitor and the rectifier bus capacitor are usually independent components that need to be connected through longer connecting wires, which takes up additional space. In this embodiment, by integrating the film capacitors 300, these capacitors are integrated into the interior of the housing 100 of the motor controller 1, which significantly reduces the space occupancy and makes the entire system more compact.

[0052] The film capacitor 300 is fixed to the box body 100 by means of positioning pins and bolts.

[0053] In the present embodiment, the film capacitor 300 further comprises a positive copper bar 340, a negative copper bar 360 and a positive boost copper bar 350, wherein the negative copper bar 360 is electrically connected to the negative terminal of the boost capacitor 320 and at least one rectifier bus capacitor 330, the positive copper bar 340 is electrically connected to the positive terminal of the at least one rectifier bus capacitor 330, and the positive boost copper bar 350 is electrically connected to the positive terminal of the boost capacitor 320. That is to say, the negative terminals of all capacitors are connected to the same negative copper bar 360, while the positive terminals are connected to the copper bars by classification, the positive terminal of the boost capacitor 320 is connected to the positive boost copper bar 350, and at least one rectifier bus capacitor 330 is connected to the same positive copper bar 340. With such a design, the connection between capacitors can be simplified, the number and complexity of connecting wires can be reduced, and production efficiency can be improved.

[0054] In this embodiment, the negative copper busbar 360 is arranged at the bottom of the shell 310, and a connecting plate is provided at the edge of the negative copper busbar 360, which is perpendicular to the negative copper busbar 360, and the connecting plate is attached to the inner wall of the shell 310, and the connecting plate is provided with a negative sub-connecting plate 361 perpendicular to it, and the negative sub-connecting plate 361 is arranged outside the shell 310; the positive copper busbar 340 is provided with a positive sub-connecting plate 341 corresponding to the negative sub-connecting plate 361, and each of the negative sub-connecting plate 361 and each of the positive sub-connecting plate 341 form an electrical connection port, and this embodiment has a first electrical connection port 370 and a second electrical connection port 380 arranged at intervals.

[0055] It should be noted that the connection plates or positive and negative electrode connection plates 361 on the power module 200 and the film capacitor 300 are provided with connection holes for convenient bolt fixing. The opening of the housing 310 is provided with a support platform 311 for an electrical connection port, and the support platform 311 has two, and each support platform 311 is provided with two holes for fixing the electrical connection port.

[0056] In this embodiment, combined with reference Figure 1 The film capacitor 300 is electrically connected to the power module 200, and the plurality of pairs of connecting copper bars are electrically connected to the positive connecting plate 341 and the negative connecting plate 361 respectively. The first copper bar pair 241 and the second copper bar pair 242 of the power module 200 are respectively connected to the first electrical connection port 370 and the second electrical connection port 380 of the film capacitor 300, and are fixed to the support platform 311 by bolts.

[0057] It can be understood that the power module 200 and the thin film capacitor 300 are directly connected through the copper busbars provided on their respective bodies. This method replaces the traditional wire connection method. While ensuring effective internal connection, it reduces the connecting elements in the circuit, thereby simplifying the circuit layout, reducing the volume and complexity of the circuit, improving manufacturing efficiency and reliability, and also improving the space utilization of the internal space of the motor controller 1.

[0058] In addition, in this embodiment, the copper busbars for the film capacitor 300 and the power module 200 are designed for compactness and stability of the connection of the internal components of the motor controller 1. This embodiment only proposes a feasible connection structure, and different connection structures or connection methods can be adopted for different needs.

[0059] In this embodiment, combined with reference Figure 1 , also includes a circuit board 400, which is arranged in the accommodating cavity 110, and the circuit board 400 integrates a control circuit and a power circuit, and the circuit board 400 has a plurality of connecting parts 410. The circuit board 400 is limited by two positioning pins and is fixed to the box body 100 by ten screws. The circuit board 400 integrates a control circuit and a power circuit, which can monitor and control the operating status of the boost module and communicate with other system components. By integrating the control circuit and the power circuit on the same circuit board 400, the use of additional components and connecting lines can be avoided, thereby reducing the volume of the overall motor controller 1, making it more compact, and the EMC performance is also improved.

[0060] It should be noted that the power module 200 has a plurality of pins 250, and the overmolded component 240 has a plurality of holes 246. After the overmolded component 240 is installed on the power module 200, the pins 250 will extend out and be exposed outside the overmolded component 240. The exposed pins 250 are inserted into the connecting portion 410 of the circuit board 400 and fixed by welding to achieve electrical connection.

[0061] The circuit board 400 is provided with a connector, which is connected to the terminal input harness 30; the terminal input harness 30 is fixed to the box body 100 by two bolts.

[0062] The multiple connection parts 410 of the circuit board 400 are not only used for welding with the power module 200 , but also used for welding and fixing with the Hall chip 40 disposed in the Hall chip limiting hole 245 .

[0063] In this embodiment, combined with reference Figure 1The motor controller 1 further includes a boost inductor 500, which is disposed in the accommodating cavity 110. The output end of the boost inductor 500 is electrically connected to the positive boost copper busbar 350 of the film capacitor 300, and the input end of the boost inductor 500 is electrically connected to the third copper busbar pair 243 of the power module 200. The boost inductor 500 is fixed to the box body 100 by four bolts.

[0064] It is understandable that the boost inductor 500, the boost capacitor 320, the boost power device 220 and part of the circuit board 400 cooperate with each other, and the circuit board 400 integrates the control circuit and the power circuit, and is also connected to the boost inductor 500, the boost capacitor 320 and the boost power device 220, which can monitor and control the operating status of the boost module and ensure that they can work in coordination and achieve the expected voltage boost function. Therefore, the boost inductor 500, the boost capacitor 320, and the boost power device 220 together constitute the boost module of the motor controller 1, which improves the stability of the output voltage and can quickly charge the battery.

[0065] In this embodiment, combined with reference Figure 1 The motor controller 1 also includes an EMC filter component 10, which is limited by two positioning pins and fixed to the box body 100 by three screws.

[0066] The positive boost copper busbar 350 of the power module 200 has a positive boost sub-connection plate 351 extending outside the shell 310 of the film capacitor 300, and the positive and negative copper busbars 360 at the input end of the EMC filter component 10 are respectively connected to the positive boost sub-connection plate 351 and one of the negative sub-connection plates 361 of the film capacitor 300 by screws; the positive and negative copper busbars 360 at the output end of the EMC filter component 10 are electrically connected to the high-voltage connector by screws.

[0067] The utility model also proposes a new energy vehicle, which includes a motor and a motor controller, wherein the motor controller is the above-mentioned integrated motor controller 1, and its specific structure refers to the above-mentioned embodiment. Since the test pipeline adopts all the technical solutions of all the above-mentioned embodiments, it has at least all the beneficial effects brought by the technical solutions of the above-mentioned embodiments, which will not be repeated here one by one.

[0068] In this embodiment, the integrated motor control has a first water channel 600 that runs through the accommodating cavity 110, and the motor has a second water channel. The size of the first water channel 600 matches the size of the second water channel, and the first water channel 600 and the second water channel are connected to form a common water channel. The shared water channel design has significant beneficial effects in terms of system simplification, space optimization, energy saving and consumption reduction, improved thermal management efficiency, cost reduction, and reliability enhancement, which has obvious advantages over independent water channel design.

[0069] In summary, the utility model discloses an integrated motor controller, which effectively integrates multiple functional modules, reduces the size of the motor controller, improves the space utilization of the motor controller, and also improves the internal space utilization of the whole vehicle, which is convenient for installation and arrangement inside the vehicle, and maintains good mechanical strength and safety. The integrated motor controller mainly includes a box, a film capacitor and a power module. A shell is provided inside the film capacitor, and a boost capacitor and at least one rectifier bus capacitor are arranged in order in the shell, and electrical connection is achieved through a positive copper bus, a negative copper bus and a positive boost copper bus, wherein a positive sub-connection plate and a negative sub-connection plate are specially designed, and the connecting copper bus of the power module is matched to form an efficient and compact electrical connection structure. The power module integrates a plurality of boost power devices and a plurality of rectifier power devices and a heat sink, and all circuit elements are arranged on both sides of a plane of the heat sink, and are electrically connected to the film capacitor through a connecting copper bus. The entire motor controller is reasonably designed and fully utilizes the internal space. Not only are the filter components, high-voltage connectors, boost inductors, circuit boards (including control boards and power boards) and copper busbar components rationally arranged in the accommodating cavity, but the capacitors and power modules are also efficiently integrated, and the design of the circuit boards and water channels is also improved, which greatly increases the utilization of the internal space and thus reduces the overall volume and complexity of the controller.

[0070] The above description is only a preferred 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. An integrated motor controller, characterized in that: include: A box body, wherein one side of the box body has a receiving cavity; A power module is disposed in the accommodating cavity, and the power module has a heat dissipation plate; as well as, A plurality of boost power devices and a plurality of rectifier power devices are respectively arranged on two sides of the heat sink.

2. The integrated motor controller according to claim 1, characterized in that: The power module also has: A plastic overmolding assembly, wherein the power module is covered by the plastic overmolding assembly, a copper busbar assembly is arranged inside the plastic overmolding assembly, the copper busbar assembly is electrically connected to a plurality of boost power devices and a plurality of rectifier power devices on the power module, and a plurality of pairs of connecting copper busbars are extended from the side of the plastic overmolding assembly for electrical connection between the power module and other electrical components.

3. The integrated motor controller according to claim 2, characterized in that: It also includes a film capacitor, which is arranged in the accommodating cavity. The film capacitor has a shell, a boost capacitor and at least one rectifier bus capacitor arranged in the shell.

4. The integrated motor controller according to claim 3, characterized in that: The film capacitor also includes a positive copper bar, a negative copper bar and a positive boost copper bar. The negative copper bar is electrically connected to the negative terminal of the boost capacitor and the at least one rectifier bus capacitor, the positive copper bar is electrically connected to the positive terminal of the at least one rectifier bus capacitor, and the positive boost copper bar is electrically connected to the positive terminal of the boost capacitor.

5. The integrated motor controller according to claim 4, characterized in that: The negative copper bar is arranged at the bottom of the shell, and a plurality of connecting plates are arranged perpendicularly to the negative copper bar at the edge of the negative copper bar, and the plurality of connecting plates are attached to the inner wall of the shell, and each connecting plate is provided with a negative sub-connecting plate perpendicular to it, and the negative sub-connecting plate is arranged outside the shell; The positive electrode copper busbar is provided with a positive electrode connecting plate corresponding to the negative electrode connecting plate, and each of the negative electrode connecting plates and each of the positive electrode connecting plates form an electrical connection port.

6. The integrated motor controller according to claim 5, characterized in that: The film capacitor is electrically connected to the power module, and a plurality of pairs of connecting copper bars are electrically connected to the electrical connection ports correspondingly.

7. The integrated motor controller according to any one of claims 1 to 5, characterized in that: The motor controller further comprises a circuit board, which is arranged in the accommodating cavity. The circuit board integrates a control circuit and a power circuit. The power module has a plurality of pins, and the circuit board has a plurality of connecting parts for welding with the pins.

8. The integrated motor controller according to claim 3, characterized in that: The motor controller further includes a boost inductor disposed in the accommodating cavity, wherein an output end of the boost inductor is electrically connected to the film capacitor, and an input end of the boost inductor is electrically connected to the power module.

9. A new energy vehicle, characterized in that: The new energy vehicle comprises a motor and an integrated motor controller as described in any one of claims 1 to 8.

10. The new energy vehicle according to claim 9, characterized in that: The integrated motor control has a first water channel that runs through the accommodating cavity, and the motor has a second water channel. The size of the first water channel matches the size of the second water channel, and the first water channel and the second water channel are connected to form a common water channel.

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