Inverter brick assembly for electric automobile and controller thereof

Abstract

The utility model provides an inversion brick assembly used for an electric automobile and a controller thereof, and the inversion brick assembly comprises a supporting plate, one side of the supporting plate is provided with an accommodation space, and at least one surface of the accommodation space is a heat dissipation plate; the bus capacitor is mounted in the accommodating space; the water cooling plate is arranged on one side of the supporting plate and is arranged in parallel with the bus capacitor; the IGBT module is arranged between the water cooling plate and the supporting plate and is electrically connected with the bus capacitor; the control circuit board is arranged on the side, away from the containing space, of the supporting plate and electrically connected with the IGBT module. According to the utility model, the overall height of the inversion brick is effectively reduced, a metal plate is used to replace a traditional plastic housing, thermal resistance on a heat radiation path in the bus capacitor is reduced, the performance of the bus capacitor is exerted to a greater extent, mechanical strength is increased, an anti-vibration level is improved, and high integration is realized. The die cost, the production cost and the maintenance cost can be reduced, and the production efficiency is improved.

Description

Technical Field

[0001] The utility model belongs to the technical field of electric vehicle controllers, and specifically relates to an inverter brick component used for an electric vehicle and a controller thereof. Background Art

[0002] Faced with the cost and volume pressure of electronic control components, existing new energy vehicles usually use an all-in-one controller, which uses a box and integrates a lot of components inside the box. However, due to the wide variety of components inside the controller and the relatively complex structure, especially the close mechanical connection between the components, it is difficult to diagnose and repair faults in the later stage, which increases the cost of after-sales service; on the other hand, due to the large number of components and their relative dispersion, it is difficult to assemble, which also reduces the reliability and stability of the controller assembly.

[0003] Therefore, optimizing volume structure, reducing failure probability and lowering maintenance costs are key in the development process of all-in-one controllers. Utility Model Content

[0004] In view of the above shortcomings of the prior art, the purpose of the present utility model is to provide an inverter brick assembly for an electric vehicle and its controller, so as to solve the problem that the existing controller has a relatively complex structure, which makes later fault diagnosis and repair more difficult, increases the cost of after-sales service, increases the difficulty of assembly, and reduces the reliability and stability of the controller assembly.

[0005] To achieve the above-mentioned purpose and other related purposes, the utility model provides an inverter brick assembly for an electric vehicle controller, comprising:

[0006] A support plate, wherein a receiving space is formed on one side of the support plate, and a plate member on at least one side of the receiving space is a heat dissipation plate;

[0007] A bus capacitor, wherein the bus capacitor is installed in the accommodating space;

[0008] A water-cooling plate, the water-cooling plate is arranged on one side of the support plate, and is located on the same side of the support plate as the bus capacitor, and is arranged in parallel with the bus capacitor;

[0009] An IGBT module, the IGBT module is arranged between the water cooling plate and the support plate, and is electrically connected to the bus capacitor;

[0010] A control circuit board is arranged on a side of the support plate away from the accommodating space and is electrically connected to the IGBT module.

[0011] In one embodiment of the present invention, the support plate includes a top support plate, a bottom support plate and a plurality of side support plates, and the plurality of side support plates are fixedly connected between the top support plate and the bottom support plate and enclose to form the accommodating space.

[0012] In one embodiment of the present invention, the side support plate and the top support plate are an integrally formed structure.

[0013] In an embodiment of the present invention, the support plate is a metal plate.

[0014] In an embodiment of the present invention, a metal shell is disposed on one side of the support plate, the accommodating space is formed in the metal shell, and the metal shell is fixedly connected to the support plate.

[0015] In one embodiment of the present invention, the plate located on the bottom surface of the accommodating space is the heat dissipation plate and / or at least one plate located on the side surface of the accommodating space is the heat dissipation plate.

[0016] In one embodiment of the utility model, the IGBT module is electrically connected to the bus capacitor via a copper busbar, and the copper busbar is led out from a side close to the water cooling plate.

[0017] In an embodiment of the present invention, each surface of the accommodating space and the bus capacitor are filled with potting glue.

[0018] In one embodiment of the present invention, there is a gap between the control circuit board and the support plate.

[0019] The utility model also provides an electric vehicle, characterized in that it comprises a controller, wherein the controller comprises an inverter brick assembly for the electric vehicle controller as described in any one of the above embodiments.

[0020] The utility model provides an inverter brick assembly for an electric vehicle and its controller, by arranging a bus capacitor and an IGBT module in parallel on the bottom surface of a support plate, that is, the bus capacitor is assembled on the side of the IGBT module and integrated with the support plate as a whole, thereby effectively reducing the overall height of the inverter brick.

[0021] The utility model proposes an inverter brick assembly for an electric vehicle and a controller thereof, which reduces the thermal resistance on the internal heat dissipation path of the bus capacitor by installing a bus capacitor in a accommodating space on one side of a support plate, and fills a potting compound between the side wall of the accommodating space and the bus capacitor, and replaces the traditional plastic shell with a metal plate, thereby overcoming the heat dissipation problem and bringing the performance of the bus capacitor into play to a greater extent; and by directly installing the bus capacitor in the accommodating space and fixing it with the potting compound, the volume of the bus capacitor is effectively reduced compared with the traditional structure, and the mechanical assembly process in the traditional solution can be omitted, thereby improving the reliability of the product and effectively reducing the cost investment of factory assembly; and the bus capacitor adopts a metal shell, which increases the mechanical strength and improves the vibration resistance level compared with the traditional solution.

[0022] The utility model provides an inverter brick assembly for an electric vehicle and a controller thereof, which integrates various components together to realize a highly integrated inverter brick solution, thereby reducing mold costs, production costs and maintenance costs and improving production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the technical solutions of the embodiments of the utility model, the drawings required for describing the embodiments are briefly introduced below. Obviously, the drawings described below are only some embodiments of the utility model. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0024] Figure 1 The utility model is a schematic structural diagram of an inverter brick assembly for an electric vehicle controller in one embodiment.

[0025] Figure 2 The utility model is an exploded schematic diagram of an inverter brick assembly for an electric vehicle controller in one embodiment.

[0026] Description of labels:

[0027] 100. Inverter brick assembly; 10. Support plate; 20. Bus capacitor; 30. Water cooling plate; 11. Top support plate; 12. Bottom support plate; 13. Side support plate; 101. Heat sink; 40. IGBT module; 401. Copper busbar; 402. Three-phase copper busbar; 50. Control circuit board. DETAILED DESCRIPTION

[0028] The following is an explanation of the implementation of the present invention through specific examples, and those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. The present invention can also be implemented or applied through other different specific implementations, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention.

[0029] It should be noted that the illustrations provided in this embodiment are only used to schematically illustrate the basic concept of the present invention. Therefore, the drawings only show components related to the present invention rather than being drawn according to the number, shape and size of components in actual implementation. In actual implementation, the type, quantity and proportion of each component may be changed arbitrarily, and the component layout may also be more complicated.

[0030] See also Figure 1 and Figure 2 As shown in the figure, facing the cost and volume pressure of electronic control components, new energy vehicle manufacturers gradually adopt the all-in-one controller solution, that is, the all-in-one controller uses a box, and then integrates a lot of components inside the box. Due to the large number of components, the structure is relatively complex. In order to reduce the volume of the controller, these internal components are closely mechanically related to each other. To remove a component, the related structural parts must be disassembled one by one, which makes it difficult to diagnose and repair faults in the later stage, and increases the cost of after-sales service. On the other hand, due to the large number of components and their relative dispersion, the assembly of the controller is difficult during the manufacturing process, which also reduces the reliability and stability of the controller assembly.

[0031] Therefore, optimizing the volume structure, reducing the probability of failure and reducing maintenance costs are the key in the development process of all-in-one controllers. For the inverter brick assembly for new energy vehicle controllers, which is mainly composed of a control circuit board, a support plate, an IGBT module, a water-cooled plate, a bus capacitor and a three-phase copper busbar, there are generally two existing optimization methods. One is to adopt a stacked structure, and place the control circuit board, support plate, IGBT module, water-cooled plate and bus capacitor in order from top to bottom. The control circuit board is fixed to the support plate by bolts and electrically connected to the IGBT module. The three-phase copper busbar is connected to the IGBT module on the side. This structure leads to the problem of large height dimensions of the device. In addition, the other sides of the bus capacitor still use plastic shells, which need to be molded separately, increasing the R&D and manufacturing costs. The other is to adopt a flat structure, place the water-cooled plate on the side of the bus capacitor, reduce the overall height, and fit the bottom of the bus capacitor with the water-cooled plate for internal heat dissipation, but the other sides still use plastic shells, which have large thermal resistance. In the above two solutions, the bus capacitor and the water-cooling plate are connected mechanically, which is large in size, increases the factory assembly process and reduces the reliability of the product, and still cannot solve the high cost problem.

[0032] Therefore, the present application proposes an inverter brick assembly for an electric vehicle and its controller to solve the problem that the existing controller has a relatively complex structure, which makes later fault diagnosis and repair more difficult, increases the cost of after-sales service, increases the difficulty of assembly, and reduces the reliability and stability of the controller assembly, as well as the problems existing in the above-mentioned existing solutions.

[0033] See also Figure 1 and Figure 2 As shown, in this embodiment, the inverter brick assembly 100 includes a support plate 10, a bus capacitor 20 and a water-cooling plate 30. An accommodating space is formed on one side of the support plate 10, the bus capacitor 20 is installed in the accommodating space, and the water-cooling plate 30 is arranged on one side of the support plate 10. Specifically, the water-cooling plate 30 and the bus capacitor 20 are located on the same side of the support plate 10, and are arranged in parallel with the bus capacitor 20, that is, the water-cooling plate 30 is placed on the side of the bus capacitor 20, which effectively reduces the overall height of the device.

[0034] See also Figure 1 and Figure 2 As shown, in this embodiment, the accommodation space may be a space enclosed by a part of the plate members of the support plate 10, or may be an independent shell fixedly connected to the support plate 10 by bolts or other means, and the accommodation space is formed in the shell. In this embodiment, the plate member located at the bottom of the accommodation space is designed as a heat sink 101 and / or at least the plate member located at the side of the accommodation space is designed as a heat sink 101, so as to ensure the heat dissipation effect of the bus capacitor 20 and make the bus capacitor 20 perform its performance to a greater extent.

[0035] See also Figure 1 and Figure 2 As shown, in this embodiment, the support plate 10 includes a top support plate 11, a bottom support plate 12 and a plurality of side support plates 13, and the plurality of side support plates 13 are fixedly connected between the top support plate 11 and the bottom support plate 12, and the top support plate 11, the bottom support plate 12 and the plurality of side support plates 13 enclose the accommodation space to accommodate and install the bus capacitor 20, so as to integrate the bus capacitor 20 and the support plate 10 into a whole, which is conducive to the high integration of the inverter brick assembly 100, can reduce the production cost and maintenance cost, and improve the production efficiency. It can be understood that in this embodiment, the length of the top support plate 11 is greater than that of the bottom support plate 12, and the accommodation space is located at one end of the top support plate 11, so as to facilitate the assembly of structures such as the water cooling plate 30 and the IGBT module 40 with the top support plate 11.

[0036] See also Figure 1 and Figure 2 As shown, in this embodiment, the top support plate 11 and the side support plate 13 are an integrally formed structure, which is conducive to the integration of the inverter brick assembly 100, and can reduce mold costs and improve production efficiency. In this embodiment, the top support plate 11 and the side support plate 13 serve as part of the shell of the bus capacitor 20. At the same time, the support plate 10 is a metal plate. The metal shell replaces the traditional plastic shell. Compared with the traditional solution, the shell part of the bus capacitor 20 does not need to be molded separately, which effectively reduces its production cost, and can also increase its mechanical strength and improve the vibration resistance level.

[0037] See also Figure 1 and Figure 2 As shown, in this embodiment, the bottom support plate 12 is set as a heat sink, which can ensure the heat dissipation effect of the bus capacitor 20 and maximize the performance of the bus capacitor 20. In some other embodiments, one or more of the multiple side support plates 13 in the support plate 10 can also be set as a heat sink to further improve its heat dissipation effect. In this embodiment, the bottom support plate 12 can be fixedly connected to the side support plate 13 described in the above embodiment separately, which is conducive to the assembly of the bus capacitor 20. Of course, in some other embodiments, the bottom support plate 12 can also be an integrally formed structure with the side support plate 13.

[0038] See also Figure 1 and Figure 2 As shown, in the present embodiment, the accommodation space formed by the top support plate 11, the bottom support plate 12 and the plurality of side support plates 13 is designed as an open structure on a side close to the water-cooled plate 30, so as to facilitate the injection of potting glue and fill it between each surface of the accommodation space and the bus capacitor 20. The potting glue can effectively improve the heat dissipation effect of the bus capacitor 20. At the same time, the potting glue can also be used for fixing, fixing the bus capacitor 20 in the accommodation space, so as to facilitate the integration of the bus capacitor 20 and the support plate 10 into a whole, which is beneficial to the high integration of the inverter brick assembly 100. At the same time, by directly installing the bus capacitor 20 in the accommodation space and fixing it by potting glue, the volume of the bus capacitor 20 is effectively reduced compared with the traditional structure, and the mechanical assembly process in the traditional solution can be omitted, thereby improving the reliability of the product and effectively reducing the cost investment of factory assembly.

[0039] In some other embodiments, an independent metal shell can be provided on one side of the support plate 10, and the metal shell is fixedly connected to the support plate 10, and a housing space is formed in the metal shell to accommodate the bus capacitor 20. The metal shell is used as the shell of the bus capacitor 20 to replace the traditional plastic shell, thereby reducing the thermal resistance on the internal heat dissipation path of the bus capacitor 20, overcoming the heat dissipation problem, and giving full play to the performance of the bus capacitor 20. At the same time, compared with the traditional solution, it can also increase the mechanical strength and improve the vibration resistance level. A potting glue is poured between each surface of the metal shell and the bus capacitor 20, and the potting glue can effectively improve the heat dissipation effect of the bus capacitor 20, and the bus capacitor 20 can also be fixed in the housing space. It can be understood that the plate located on the bottom of the metal shell can be set as a heat dissipation plate and / or at least one plate located on the side of the metal shell can be set as a heat dissipation plate to ensure the heat dissipation effect of the bus capacitor 20, so that the performance of the bus capacitor 20 can be given full play.

[0040] See also Figure 1 and Figure 2 As shown, in this embodiment, the inverter brick assembly 100 further includes an IGBT module 40 and a control circuit board 50. The IGBT module 40 is arranged between the water-cooled plate 30 and the support plate 10, and is electrically connected to the bus capacitor 20. The bus capacitor 20 and the IGBT module 40 are electrically connected through a copper bus 401. Specifically, the copper bus 401 is led out from a side close to the water-cooled plate 30 to electrically connect the bus capacitor 20 and the IGBT module 40. At the same time, a three-phase copper bus 402 is connected to the side of the IGBT module 40 away from the bus capacitor 20. The control circuit board 50 is arranged on a side of the support plate 10 away from the accommodating space, and is electrically connected to the IGBT module 40. It can be understood that there is a gap between the control circuit board 50 and the support plate 10 to prevent the heat conduction of the support plate 10 from transferring heat to the control circuit board 50, thereby affecting the performance and safety of the control circuit board 50, and the existence of the gap is conducive to the heat dissipation of the control circuit board 50 and the bus capacitor 20.

[0041] The utility model further provides an electric vehicle, including a controller, wherein the controller includes an inverter brick assembly 100 as described in the above embodiment. The structure of the inverter brick assembly 100 is the same as or similar to the structure described in the above embodiment, and will not be described again to avoid repetition.

[0042] The utility model provides an inverter brick assembly for an electric vehicle and its controller, by arranging a bus capacitor and an IGBT module in parallel on the bottom surface of a support plate, that is, the bus capacitor is assembled on the side of the IGBT module and integrated with the support plate as a whole, thereby effectively reducing the overall height of the inverter brick.

[0043] The utility model proposes an inverter brick assembly for an electric vehicle and a controller thereof, which reduces the thermal resistance on the internal heat dissipation path of the bus capacitor by installing a bus capacitor in a accommodating space on one side of a support plate, and fills a potting compound between the side wall of the accommodating space and the bus capacitor, and replaces the traditional plastic shell with a metal plate, thereby overcoming the heat dissipation problem and bringing the performance of the bus capacitor into play to a greater extent; and by directly installing the bus capacitor in the accommodating space and fixing it with the potting compound, the volume of the bus capacitor is effectively reduced compared with the traditional structure, and the mechanical assembly process in the traditional solution can be omitted, thereby improving the reliability of the product and effectively reducing the cost investment of factory assembly; and the bus capacitor adopts a metal shell, which increases the mechanical strength and improves the vibration resistance level compared with the traditional solution.

[0044] The utility model provides an inverter brick assembly for an electric vehicle and a controller thereof, which integrates various components together to realize a highly integrated inverter brick solution, thereby reducing mold costs, production costs and maintenance costs and improving production efficiency.

[0045] The embodiments described above are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features may be replaced by equivalents. Such modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention, and should be included in the protection scope of the present invention.

[0046] Except for the technical features described in the specification, the other technical features are known technologies to those skilled in the art. In order to highlight the innovative features of the present utility model, the other technical features will not be described in detail here.

Claims

1. An inverter brick assembly for an electric vehicle controller, characterized in that: include: A support plate, wherein a receiving space is formed on one side of the support plate, and a plate member on at least one side of the receiving space is a heat dissipation plate; A bus capacitor, wherein the bus capacitor is installed in the accommodating space; A water-cooling plate, the water-cooling plate is arranged on one side of the support plate, and is located on the same side of the support plate as the bus capacitor, and is arranged in parallel with the bus capacitor; An IGBT module, the IGBT module is arranged between the water cooling plate and the support plate, and is electrically connected to the bus capacitor; A control circuit board is arranged on a side of the support plate away from the accommodating space and is electrically connected to the IGBT module.

2. The inverter brick assembly for an electric vehicle controller according to claim 1, characterized in that: The support plate includes a top support plate, a bottom support plate and a plurality of side support plates, and the plurality of side support plates are fixedly connected between the top support plate and the bottom support plate and enclose the accommodating space.

3. The inverter brick assembly for the electric vehicle controller according to claim 2, characterized in that: The side support plate and the top support plate are an integrally formed structure.

4. The inverter brick assembly for an electric vehicle controller according to claim 2, characterized in that: The support plate is a metal plate.

5. The inverter brick assembly for an electric vehicle controller according to claim 1, characterized in that: A metal shell is disposed on one side of the support plate, the accommodating space is formed in the metal shell, and the metal shell is fixedly connected to the support plate.

6. The inverter brick assembly for an electric vehicle controller according to claim 2 or 5, characterized in that: The plate component located at the bottom surface of the accommodating space is the heat dissipation plate and / or at least one plate component located at the side surface of the accommodating space is the heat dissipation plate.

7. The inverter brick assembly for an electric vehicle controller according to claim 2 or 5, characterized in that: The IGBT module is electrically connected to the bus capacitor via a copper busbar, and the copper busbar is led out from a side close to the water cooling plate.

8. The inverter brick assembly for an electric vehicle controller according to claim 2 or 5, characterized in that: Potting glue is filled between each surface of the accommodating space and the bus capacitor.

9. The inverter brick assembly for an electric vehicle controller according to claim 1, characterized in that: There is a gap between the control circuit board and the support plate.

10. An electric vehicle, characterized in that: It comprises a controller, wherein the controller comprises an inverter brick assembly for an electric vehicle controller as claimed in any one of claims 1 to 9.

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