Motor controller integrated module, power supply device and electric vehicle

Abstract

The utility model provides a motor controller integrated module, a power supply device and an electric vehicle, the motor controller integrated module integrates a bus capacitor, a radiator and two groups of power modules, the bus capacitor comprises a shell and a capacitor core package, the shell comprises an accommodating groove, the accommodating groove is used for accommodating the capacitor core package, and the capacitor core package is arranged in the accommodating groove. The length of the capacitor core bag in the width direction is smaller than the length of the capacitor core bag in the length direction, and the groove peripheral wall of the containing groove comprises two first side walls opposite to each other in the width direction of the capacitor core bag. The two groups of power modules are laminated with a heat dissipation plate of the heat sink along the width direction of the capacitor core package and are arranged on one side, deviating from the other first side wall, of one first side wall, each group of power modules comprises three power modules, and the thickness direction of each power module is parallel to the width direction of the capacitor core package; the bus capacitor and the two groups of power modules are stacked, so that the size of the motor controller integrated module is reduced, the size of the power supply device is further reduced, and the layout of the whole vehicle is optimized.

Description

Technical Field

[0001] The present application relates to the technical field of electric vehicles, and in particular to a motor controller integrated module, a power supply device and an electric vehicle. Background Art

[0002] In the current electric vehicle hybrid field, the powertrain includes an electric motor, a generator and a motor controller. The motor controller has two sets of power modules for electrically connecting the electric motor and the generator, which increases the number of electrical components in the motor controller and makes the layout complicated. Since the powertrain is arranged in the front cabin, the space size requirements are high. Reducing the size of the motor controller with two sets of power modules is an important difficulty in the miniaturization design of the powertrain. At present, the motor controller generally adopts the design of laying two sets of power modules flat, which has problems such as low space utilization, low integration, complex production and processing procedures, and high cost. Utility Model Content

[0003] The present application provides a motor controller integrated module, a power supply device and an electric vehicle.

[0004] In the first aspect, the present application provides a motor controller integrated module, which integrates a bus capacitor, a heat sink and two groups of power modules. A bus capacitor includes a shell and a capacitor core package. A shell is used to fix a heat sink and two groups of power modules. Each group of power modules is used to realize the mutual conversion between direct current and a group of three-phase alternating current. A capacitor core package is used to electrically connect one end of each group of power modules for transmitting direct current, and a heat sink is used to cool the two groups of power modules. Among them, a shell includes a receiving groove, a receiving groove is used to receive a capacitor core package, the length of a capacitor core package along its width direction is less than the length of a capacitor core package along its length direction, and the groove peripheral wall of a receiving groove includes two first side walls, and the two first side walls are opposite to each other along the width direction of a capacitor core package. A radiator includes a heat sink. Two groups of power modules are stacked with the heat sink along the width direction of a capacitor core package and are arranged on a side of a first side wall away from another first side wall. Each group of power modules includes three power modules. The three power modules are arranged in sequence along the length direction of a capacitor core package, and the thickness direction of each power module is parallel to the width direction of a capacitor core package.

[0005] In the embodiment of the present application, the motor controller integrated module sets a capacitor core package along its width direction to be smaller, so that a capacitor core package occupies a smaller space of the motor controller integrated module along the width direction of a capacitor core package, and then a capacitor core package can be reserved along its width direction for arranging a radiator and two groups of power modules. The two groups of power modules are stacked with a heat sink and arranged on the outside of a first side wall of a receiving groove along the width direction, and the thickness direction of each power module is parallel to the width direction of a capacitor core package, so that the two groups of power modules and a heat sink are more compactly arranged on one side of a capacitor core package along its width direction, so that the two groups of power modules and a heat sink do not occupy too much space of the motor controller integrated module along the length direction of a capacitor core package, and then the volume of the motor control integrated module along the width direction of a capacitor core package and along the length direction of a capacitor core package are both smaller, so that the overall volume of the motor controller integrated module is small, and then the volume of the power supply device is small, which is conducive to the layout of the power supply device in the whole vehicle.

[0006] In one embodiment, the length of a capacitor core package along its length direction is greater than the sum of the lengths of two groups of power modules and a heat sink along the width direction of the capacitor core package.

[0007] In an embodiment of the present application, the length of a capacitor core package along its length direction is greater than the sum of the lengths of two groups of power modules and a heat sink along the width direction of the capacitor core package, so that although the two groups of power modules and one heat sink are stacked along the width direction of the capacitor core package and arranged on a first side wall, they will not occupy too much space of the motor controller integrated module along the width direction of the capacitor core package, which is beneficial to the integration of two groups of power modules, a heat sink and a capacitor core package without making the overall volume of the motor controller integrated module relatively large, and is beneficial to the miniaturized layout of the motor controller integrated module.

[0008] In one embodiment, the length of a first side wall along the length direction of a capacitor core package is greater than the spacing between two first side walls along the width direction of a capacitor core package, and the length of a first side wall along the length direction of a capacitor core package is greater than the sum of the lengths of two groups of power modules and a heat sink along the width direction of a capacitor core package.

[0009] In the embodiment of the present application, the length of a first side wall along the length direction of a capacitor core package is greater than the spacing between two first side walls along the width direction of a capacitor core package, and the space occupied by two first side walls of a receiving groove along the width direction of a capacitor core package is very small, which is conducive to a capacitor core package between the two first side walls having a smaller volume along its width direction. The length of a first side wall along the length direction of a capacitor core package is greater than the sum of the lengths of two groups of power modules and a heat sink along the width direction of a capacitor core package, and the space occupied by two groups of power modules and a heat sink along the width direction of a capacitor core package is small, which is conducive to the miniaturization of the motor controller integrated module along the width direction of a capacitor core package.

[0010] In one embodiment, along the width direction of a capacitor core package, a capacitor core package, a first side wall, a group of power modules, a heat sink and another group of power modules are arranged in sequence.

[0011] In an embodiment of the present application, a capacitor core package, a first side wall, a group of power modules, a heat sink and another group of power modules are arranged in sequence along the width direction of a capacitor core package, so that a capacitor core package, a group of power modules, a heat sink and another group of power modules will not occupy too much space of the motor controller integrated module along the length direction of a capacitor core package, so that the volume of the motor controller integrated module along the length direction of a capacitor core package is small, which is conducive to the miniaturization layout of the motor controller integrated module in the power supply device, thereby optimizing the layout of the whole vehicle. In addition, along the width direction of a capacitor core package, a heat sink is arranged between a group of power modules and another group of power modules, so that a heat sink can dissipate heat for two groups of power modules at the same time, and the heat generated by the two groups of power modules can also be absorbed by a heat sink through a short circuit, which is conducive to improving the cooling efficiency of a heat sink for two groups of power modules.

[0012] In one embodiment, a heat sink further comprises a bottom plate, and the bottom plate comprises two holes, and the two holes are used to connect the internal flow channel of a heat sink through the internal flow channel of the bottom plate. Wherein, along the width direction of a capacitor core package, a bottom plate is arranged on a side of two groups of power modules and a heat sink away from a capacitor core package. The opening direction of the two holes is the same as the notch direction of a receiving groove.

[0013] In an embodiment of the present application, a bottom plate includes two holes, and the two holes are used to receive coolant from an external cooling circulation system and output coolant after absorbing heat and heating in a radiator. The two holes are used to connect the internal flow channel of a heat sink through the internal flow channel of a bottom plate, and the internal flow channels of a heat sink and a bottom plate are connected through the two holes, so that the coolant in a radiator can flow smoothly. Among them, a bottom plate can also cool down a group of power modules adjacent to it.

[0014] In an embodiment of the present application, along the width direction of a capacitor core package, a base plate is arranged on the side of two groups of power modules and a heat sink away from a capacitor core package, so that a base plate can directly cool down the other group of power modules in the two groups of power modules. Compared with a base plate arranged on the side of two groups of power modules and a heat sink close to a capacitor core package, arranging a base plate on the side of two groups of power modules and a heat sink away from a capacitor core package is conducive to shortening the distance between a capacitor core package and two groups of power modules, and is also conducive to realizing the electrical connection of copper bars between a capacitor core package and two groups of power modules. The opening direction of the two holes is the same as the notch direction of a receiving groove, so that the position of the radiator communicating with the external waterway is in the arrangement direction of the notch of a receiving groove and the bottom of the groove, thereby not occupying the position of the motor controller integrated module along the width direction and length direction of a capacitor core package, which is conducive to reducing the volume of the motor controller integrated module.

[0015] In one embodiment, a housing further includes two fixing protrusions, the two fixing protrusions are used to fix electrical components, the two fixing protrusions are away from the one capacitor core package protrusion from the first side wall along the width direction of the one capacitor core package, and the space between the two fixing protrusions is used to accommodate a heat sink and two groups of power modules. Wherein, the spacing between the two fixing protrusions along the length direction of the one capacitor core package is greater than the length of a heat sink or each group of power modules. The length of each fixing protrusion along the width direction of the one capacitor core package is greater than the sum of the lengths of a heat sink and the two groups of power modules.

[0016] In an embodiment of the present application, the spacing between two fixed protrusions along the length direction of a capacitor core package is greater than the length of a heat sink or each group of power modules, and the arrangement space of a heat sink and two groups of power modules along the length direction of a capacitor core package is relatively small, so that the volume of the motor controller integrated module along the length direction of a capacitor core package is relatively small. The length of each fixed protrusion along the width direction of a capacitor core package is greater than the sum of the lengths of a heat sink and two groups of power modules, so that along the width direction of a capacitor core package, a heat sink and two groups of power modules are arranged in a housing of the motor controller integrated module, and the motor controller integrated module does not occupy too much space of a housing along the width direction of a capacitor core package, so that the volume of the motor controller integrated module along the width direction and length direction of a capacitor core package is relatively small.

[0017] In one embodiment, each power module includes two input copper bars and one output copper bar, the two input copper bars are used to electrically connect a capacitor core package to receive direct current, and the output copper bar is used to output one-phase alternating current. Wherein, along the arrangement direction of the bottom and notch of a receiving slot, the two input copper bars are arranged opposite to the output copper bar, the two input copper bars are on the same side as the notch of a receiving slot, the two input copper bars of each power module are arranged at intervals along the length direction of a capacitor core package, and each input copper bar is bent toward a first side wall along the width direction of a capacitor core package.

[0018] In an embodiment of the present application, along the arrangement direction of the groove bottom and the notch of a receiving groove, two input copper bars are arranged relative to an output copper bar, so that the current in each power module can be transported along the arrangement direction of the groove bottom and the notch of a receiving groove. The two input copper bars are on the same side as the notch of a receiving groove, which is conducive to the transmission of direct current between the two input copper bars of each power module and a capacitor core bag. The two input copper bars of each power module are arranged at intervals along the length direction of a capacitor core bag to avoid electrical connection interference between the two input copper bars of each power module. Each input copper bar is bent toward a first side wall along the width direction of a capacitor core bag, which is conducive to each input copper bar being electrically connected to a capacitor core bag on the other side of a first side wall, and each power module does not occupy too much space of the motor controller integrated module along the arrangement direction of the groove bottom and the notch of a receiving groove.

[0019] In one embodiment, a busbar capacitor further includes two input connection copper sheets, one input connection copper sheet is used to electrically connect the positive electrode of a capacitor core package and an input copper busbar of each power module, and the other input connection copper sheet is used to electrically connect the negative electrode of a capacitor core package and another input copper busbar of each power module. Wherein, along the arrangement direction of the bottom and notch of a receiving slot, the two input connection copper sheets are stacked and insulated. Along the arrangement direction of the bottom and notch of a receiving slot, the two input connection copper sheets are stacked on the two input copper buses of each power module.

[0020] In an embodiment of the present application, along the arrangement direction of the bottom and notch of a receiving slot, two input connection copper sheets are stacked and insulated, and the two input connection copper sheets are stacked, one input connection copper sheet is connected to the positive pole of a capacitor core package, and the other input connection copper sheet is connected to the negative pole of a capacitor core package, so that the current directions of the two input connection copper sheets are opposite. When the two input connection copper sheets are stacked, the magnetic fields generated by the two input connection copper sheets with opposite current directions can offset each other partially, thereby reducing the inductance generated by the two input connection copper sheets, so that a busbar capacitor is suitable for the application of the motor controller integrated module. Along the arrangement direction of the bottom and notch of a receiving slot, the two input connection copper sheets are stacked on the two input copper bars of each power module, which is conducive to reducing the space occupied by the two input connection copper bars and the two input copper bars of each power module along the width and length directions of a capacitor core package.

[0021] In one embodiment, three power modules in two groups of power modules are aligned along the width direction of a capacitor core package, each input connection copper sheet includes three pairs of connection holes and three pairs of avoidance holes, two connection holes in each pair of connection holes of an input connection copper sheet are respectively used to connect an input copper bar of two power modules aligned along the width direction of a capacitor core package, and two avoidance holes in each pair of avoidance holes of an input connection copper sheet are respectively used to pass through a pair of connection holes connecting another input connection copper sheet and another input copper bar of two power modules. Among them, the three pairs of connection holes and the three pairs of avoidance holes in each input connection copper sheet are alternately arranged in sequence along the length direction of a capacitor core package. Along the arrangement direction of the bottom and the notch of a receiving slot, the three pairs of connection holes of an input connection copper sheet are respectively aligned with the three pairs of avoidance holes of another input connection copper sheet.

[0022] In an embodiment of the present application, the three power modules in the two groups of power modules are aligned respectively along the width direction of a capacitor core package, which is conducive to reducing the space occupied by the two groups of power modules in the length direction of a capacitor core package. The three pairs of connection holes and the three pairs of avoidance holes in each input connection copper sheet along the length direction of a capacitor core package are arranged alternately in sequence, which facilitates the three power modules of each group of power modules connected to each input connection copper sheet to be arranged in sequence along the length direction of a capacitor core package. The three power modules in the two groups of power modules can also be aligned respectively along the width direction of a capacitor core package, thereby reducing the space occupied by the two groups of power modules in the length direction and width direction of a capacitor core package. Along the arrangement direction of the bottom and notch of a receiving groove, the three pairs of connection holes of an input connection copper sheet are aligned with the three pairs of avoidance holes of another input connection copper sheet, so that the two input connection copper sheets can be stacked and arranged along the arrangement direction of the bottom and notch of a receiving groove and insulated, which is conducive to reducing the space occupied by the two input connection copper bars along the width direction and length direction of a capacitor core package.

[0023] In an embodiment of the present application, two connection holes in each pair of connection holes of an input connecting copper sheet are respectively used to connect an input copper busbar of two power modules aligned along the width direction of a capacitor core package, and two avoidance holes in each pair of avoidance holes of an input connecting copper sheet are respectively used to pass through a pair of connection holes connecting another input connecting copper sheet and a connector of another input copper busbar of two power modules, so that one input connecting copper sheet can be electrically connected to two groups of power modules stacked along the width direction of a capacitor core package at the same time, and sharing one input connecting copper sheet and another input connecting copper sheet can improve the integration of the motor controller integrated module.

[0024] In one embodiment, two connection holes in each pair of connection holes are arranged along the width direction of a capacitor core package, and two avoidance holes in a pair of avoidance holes are arranged along the width direction of a capacitor core package. In which, along the arrangement direction of the groove bottom and the groove opening of a receiving groove, each avoidance hole is aligned with a connection hole. The aperture of each avoidance hole is larger than the aperture of a connection hole aligned with it.

[0025] In an embodiment of the present application, along the arrangement direction of the bottom and the slot opening of a receiving slot, each avoidance hole is aligned with a connection hole, so that the two avoidance holes in each pair of avoidance holes of an input connecting copper sheet are connected to a pair of connection holes of another input connecting copper sheet and the connecting parts of another input copper busbar of two power modules without occupying more space along the width and length directions of a capacitor core package.

[0026] In the embodiment of the present application, the aperture of each avoidance hole is larger than the aperture of a connection hole aligned with it, so as to facilitate the insertion of an insulating partition through each avoidance hole and avoid electrical connection between the two input connection copper sheets.

[0027] In one embodiment, an output copper bar of each power module is bent toward a first side wall along the width direction of a capacitor core package, and the motor controller integrated module also includes two groups of output connection copper sheets, each group of output connection copper sheets includes three output connection copper sheets, and the three output connection copper sheets of each group of output connection copper sheets are respectively used to connect an output copper bar of three power modules of each group of power modules. Wherein, along the arrangement direction of the bottom and notch of a receiving groove, the three output connection copper sheets of each group of output connection copper sheets are arranged on the same side as an output copper bar of each power module and are stacked on two groups of power modules and a heat sink. Along the width direction of a capacitor core package, the three output connection copper sheets of each group of output connection copper sheets extend back to a first side wall. Along the length direction of a capacitor core package, the three output connection copper sheets of one group of output connection copper sheets and the three output connection copper sheets of another group of output connection copper sheets are arranged alternately in sequence.

[0028] In an embodiment of the present application, an output copper bar of each power module is bent toward a first side wall along the width direction of a capacitor core package, which is conducive to reducing the space occupied by an output copper bar of each power module along the arrangement direction of the bottom and notch of a receiving slot. Along the arrangement direction of the bottom and notch of a receiving slot, the three output connection copper sheets of each group of output connection copper sheets are arranged on the same side as an output copper bar of each power module, which is conducive to smoothly outputting the alternating current output by an output copper bar of each power module from the three output connection copper sheets to the motor controller integrated module through a short circuit. Each group of output connection copper sheets is stacked on two groups of power modules and a heat sink, which is conducive to electrically connecting each group of output connection copper sheets to an output copper bar of each power module, and is also conducive to reducing the space occupied by each group of output connection copper sheets in the width direction of a capacitor core package and the length direction of a capacitor core package.

[0029] In an embodiment of the present application, three output connecting copper plates of one group of output connecting copper plates and three output connecting copper plates of another group of output connecting copper plates are arranged alternately in sequence along the length direction of a capacitor core package, which is beneficial to simplify the connection arrangement of the two groups of output connecting copper plates and an output copper busbar of each power module of the two groups of power modules, and is also beneficial to shorten the connection path of the two groups of output connecting copper plates and an output copper busbar of each power module of the two groups of power modules, thereby saving copper busbar material.

[0030] In one embodiment, the motor controller integrated module further integrates a circuit board, and a housing is used to fix a circuit board. Wherein, along the arrangement direction of the bottom and notch of a receiving slot, a circuit board is stacked on a housing, a heat sink and each power module, and a circuit board, a bottom of a receiving slot and a capacitor core package are arranged in sequence.

[0031] In an embodiment of the present application, along the arrangement direction of the bottom and the slot of a receiving slot, a circuit board is stacked on a shell, a heat sink and each power module, a circuit board, the bottom of a receiving slot and a capacitor core package are arranged in sequence, and a circuit board is located on the outside of the bottom of a receiving slot of a shell, so that each power module can be plugged into a circuit board through a signal plug wire to achieve electrical connection without arranging additional lines to connect the power module and the circuit board, which increases the volume of the motor controller integrated module.

[0032] In one embodiment, the motor controller integrated module also integrates an EMC filter, an EMC filter and a bus capacitor for filtering and stabilizing direct current, a slot wall of a receiving slot also includes two second side walls, the two second side walls are arranged relatively along the length direction of a capacitor core package, a capacitor core package includes two groups of capacitor cores, along the length direction of a capacitor core package, a second side wall, a group of capacitor cores, another group of capacitor cores and another second side wall are arranged in sequence. Wherein, along the width direction of a capacitor core package, the length of one group of capacitor cores is greater than the length of another group of capacitor cores. Along the width direction of a capacitor core package, a portion of another first side wall opposite to another group of capacitor cores is recessed toward another group of capacitor cores compared to another portion of another first side wall opposite to one group of capacitor cores, and a portion of another first side wall away from the space of another group of capacitor cores is used to accommodate an EMC filter.

[0033] In the embodiment of the present application, along the width direction of a capacitor core package, the length of one group of capacitor cores is greater than the length of another group of capacitor cores, thereby providing space for an EMC filter to be integrated into the motor controller integrated module, which is beneficial to improving the integration of the power supply device without making the power supply device too large. The placement of the two groups of capacitor cores only needs to satisfy the requirement that along the width direction of a capacitor core package, the length of one group of capacitor cores is greater than the length of the other group of capacitor cores so that there is enough space for an EMC filter to be integrated into the motor controller integrated module.

[0034] In an embodiment of the present application, along the width direction of a capacitor core package, a portion of another first side wall opposite to another group of capacitor cores is recessed toward the other group of capacitor cores compared to another portion of another first side wall opposite to one group of capacitor cores, and a portion of the other first side wall away from the space of the other group of capacitor cores is used to accommodate an EMC filter, which is conducive to making full use of the space on the motor controller integrated module to integrate an EMC filter, and is conducive to improving the integration of the motor controller integrated module.

[0035] In a second aspect, the present application provides a power supply device, comprising a housing and a motor controller integrated module as described in the first aspect, wherein an internal flow channel of the housing is used to connect to an internal flow channel of a heat sink in the motor controller integrated module.

[0036] In the embodiment of the present application, the motor controller integrated module is arranged in a stacked manner along the width direction of a capacitor core package through a busbar capacitor and two groups of power modules, so that the motor controller integrated module has a smaller volume along the length direction of a capacitor core package, and its volume along the width direction of a capacitor core package is also smaller, which is conducive to reducing the overall volume of the motor controller integrated module, and then reducing the volume of the power supply device, which is conducive to optimizing the layout of the whole vehicle. The internal flow channel of the housing of the power supply device is connected to the internal flow channel of a heat sink in the motor controller integrated module, making the power supply device more integrated.

[0037] In a third aspect, the present application provides an electric vehicle, comprising a frame, a power battery and a power supply device as described in the second aspect, wherein the frame is used to fix the power battery and the power supply device, the bus capacitor in the motor controller integrated module of the power supply device is used to electrically connect the power battery, and the power battery is used to drive the wheels of the electric vehicle through a motor.

[0038] In the embodiment of the present application, the motor controller integrated module in the power supply device is arranged in a stacked manner along the width direction of a capacitor core package through a bus capacitor and two groups of power modules. The motor controller integrated module has a smaller volume along the length direction of a capacitor core package and along the width direction of a capacitor core package, which makes the overall volume of the motor controller integrated module smaller, and thus makes the volume of the power supply device smaller, which is beneficial to optimizing the layout of the power supply device in the whole vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the embodiments of the present application will be described below.

[0040] Figure 1 is a schematic diagram of the structure of an electric vehicle provided in an embodiment of the present application;

[0041] Figure 2 is a schematic diagram of the structure of a powertrain provided in an embodiment of the present application;

[0042] Figure 3 is a schematic diagram of the structure of a power supply device provided in an embodiment of the present application;

[0043] Figure 4 is a schematic diagram of the structure of the motor controller integrated module provided in an embodiment of the present application;

[0044] Figure 5 yes Figure 4 Exploded view of the motor controller integrated module;

[0045] Figure 6 is another structural schematic diagram of the motor controller integrated module provided in an embodiment of the present application;

[0046] Figure 7 is another structural schematic diagram of the motor controller integrated module provided in an embodiment of the present application;

[0047] Figure 8 yes Figure 7 An exploded view of the heat sink and power module of the motor controller integrated module;

[0048] Fig. 9 is a structural schematic diagram of a housing provided in an embodiment of the present application;

[0049] Fig.10 is a schematic diagram of the structure of a power module provided in an embodiment of the present application;

[0050] Fig.11 is an exploded view of two input connection copper sheets and an insulating partition provided in an embodiment of the present application;

[0051] Fig.12 It is another structural schematic diagram of the motor controller integrated module provided in an embodiment of the present application. DETAILED DESCRIPTION

[0052] The technical solutions in the embodiments of the present application will be described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all of the embodiments.

[0053] For ease of understanding, the English abbreviations and related technical terms involved in the embodiments of the present application are explained and described below.

[0054] EMC: The abbreviation of Electro Magnetic Compatibility. EMC refers to the ability of electronic products or electrical equipment to work normally as designed in a specified electromagnetic environment.

[0055] Vertical: The verticality defined in the embodiments of the present application is not limited to an absolute vertical intersection relationship (angle of 90 degrees). It allows for a relationship that is not absolutely vertical due to factors such as assembly tolerance, design tolerance, and influence of structural flatness. It also allows for errors in a small angle range. For example, the assembly error range of 80 to 100 degrees can be understood as a vertical relationship.

[0056] Parallelism: The parallelism defined in the embodiments of the present application is not limited to absolute parallelism. This definition of parallelism can be understood as basic parallelism, which allows for situations where the absolute parallelism is not achieved due to factors such as assembly tolerance, design tolerance, and the influence of structural flatness.

[0057] The width direction of a capacitor core package is recorded as Y, the length direction of a capacitor core package is recorded as X, and the arrangement direction of the groove bottom and the groove opening of a receiving groove is recorded as Z. The directions X, Y, and Z are perpendicular to each other.

[0058] In order to reduce the volume of the power supply device and optimize the layout of the whole vehicle. The present application provides a motor controller integrated module, which integrates a bus capacitor, a radiator and two groups of power modules. A bus capacitor includes a shell and a capacitor core package. A shell is used to fix a radiator and two groups of power modules. Each group of power modules is used to realize the mutual conversion between direct current and a group of three-phase alternating current. A capacitor core package is used to electrically connect one end of each group of power modules for transmitting direct current, and a radiator is used to cool the two groups of power modules. A shell includes a receiving groove, a receiving groove is used to receive a capacitor core package, the length of a capacitor core package along its width direction is less than the length of a capacitor core package along its length direction, and the groove peripheral wall of a receiving groove includes two first side walls, and the two first side walls are opposite along the width direction of a capacitor core package. A radiator includes a heat sink, two groups of power modules are stacked with a heat sink along the width direction of a capacitor core package and arranged on a side of a first side wall away from another first side wall, each group of power modules includes three power modules, and the three power modules are sequentially spaced along the length direction of a capacitor core package, and the thickness direction of each power module is parallel to the width direction of a capacitor core package. By arranging a busbar capacitor and two groups of power modules stacked along the width direction of a capacitor core package, the motor controller integrated module has a smaller volume along the length direction of a capacitor core package, and its volume along the width direction of a capacitor core package is also smaller, which is conducive to reducing the overall volume of the motor controller integrated module, thereby reducing the volume of the power supply device, and is conducive to optimizing the layout of the entire vehicle.

[0059] The motor controller integrated module provided in the embodiment of the present application is applied to a power supply device, and the power supply device is applied to an electric vehicle to improve the overall performance of the electric vehicle.

[0060] Figure 1 This is a schematic diagram of the structure of an electric vehicle 1 provided in an embodiment of the present application. Figure 2 This is a schematic diagram of the structure of the powertrain 10 provided in an embodiment of the present application. Figure 3 A schematic diagram of the structure of the power supply device 15 provided in an embodiment of the present application.

[0061] In one embodiment, the electric vehicle 1 includes a frame 20, a power battery 30 and a powertrain 10. Figure 1 As shown, the frame 20 is used to fix the power battery 30 and the power assembly 10. In the embodiment of the present application, the electric vehicle 1 refers to a wheeled device driven or towed by a power device. In the embodiment of the present application, the power assembly 10 is used to receive power from the power battery 30 and to drive the wheel 40.

[0062] In one embodiment, the powertrain 10 includes an engine 11, a motor 12, a generator 13, a reducer 14, and a power supply device 15. Figure 1 and Figure 2 As shown, the engine 11 is used to output power. For example, the engine 11 can be a fuel engine, which includes a gasoline engine and a diesel engine. The generator 13 is connected to the engine 11 in a transmission manner, and the engine 11 provides power to the generator 13, and the generator 13 converts the kinetic energy output by the engine 11 into electrical energy. The generator 13 is electrically connected to the power battery 30, and the generator 13 can charge the power battery 30 through the power supply device 15. The motor 12 is electrically connected to the power battery 30, and the power battery 30 can supply power to the motor 12 through the power supply device 15. The motor 12 is used to convert the electrical energy output by the power battery 30 into kinetic energy. The motor 12, the generator 13 and the motor 12 are connected to the wheel 40 in a transmission manner through the reducer 14 to provide power to the wheel 40 and drive the wheel 40 to move. In one embodiment, the engine 11 provides power to the generator 13, and the generator 13 directly transmits power to the wheel 40 to drive the wheel 40 to run, thereby realizing dual-motor drive.

[0063] In an embodiment of the present application, the power supply device 15 is used to charge and discharge the power battery 30 and to drive the motor 12. The power supply device 15 is used to receive high-voltage direct current transmitted by the power battery 30, and convert the high-voltage direct current into high-voltage alternating current and transmit it to the motor 12 to drive the motor 12 to rotate. In one embodiment, the power supply device 15 is used to receive alternating current and convert the alternating current into direct current to charge the power battery 30. The alternating current includes city electricity or civil alternating current. In one embodiment, the power supply device 15 receives high-voltage direct current and provides direct current to the power battery 30 for charging.

[0064] In one embodiment, the power supply device 15 includes a motor controller integrated module 100 and at least one of an on-board charger (not shown), a power distribution module (not shown), and a vehicle controller (not shown).

[0065] The motor controller integrated module 100 is used to receive high-voltage direct current from the power battery 30 and convert the high-voltage direct current into high-voltage alternating current for transmission to the winding (not shown) of the motor 12, driving the rotor and the motor shaft of the motor 12 to rotate. The motor controller integrated module 100 can also receive the induced current generated by the generator 13 to charge the power battery 30.

[0066] In one embodiment, the bottom plate 15a of the power supply device 15 includes a liquid inlet 1501 and a liquid outlet 1502. Figure 3As shown, the liquid inlet hole 1501 and the liquid outlet hole 1502 are respectively connected to the radiator (not shown) of the motor controller integrated module 100, so that the internal flow channel 15b of the power supply device 15 shell is connected to the internal flow channel of the radiator of the motor controller integrated module 100, thereby cooling the motor controller integrated module 100.

[0067] The powertrain 10 of the hybrid electric vehicle 1 includes a generator 13 and an electric motor 12. The motor controller integrated module 100 needs to be arranged with two sets of power modules to respectively realize current conversion with the generator 13 and the electric motor 12, which makes the size of the motor controller integrated module 100 larger and the overall volume of the power supply device 15 larger, which is not conducive to the layout of the power supply device 15 in the whole vehicle.

[0068] In the embodiment of the present application, by improving the motor controller integrated module, the layout of the electrical components in the motor controller integrated module is made more compact and occupies a smaller volume, thereby reducing the overall volume of the motor controller integrated module, thereby reducing the overall volume of the power supply device 15 and optimizing the layout of the entire vehicle.

[0069] The motor controller integrated module 100 provided in an embodiment of the present application will be described in detail below.

[0070] Figure 4 This is a schematic diagram of the structure of the motor controller integrated module 100 provided in an embodiment of the present application. Figure 5 for Figure 4 An exploded diagram of the motor controller integrated module 100 in FIG. Figure 6 Another structural diagram of the motor controller integrated module 100 provided in an embodiment of the present application is shown in FIG. Figure 7 Another structural schematic diagram of the motor controller integrated module 100 provided in an embodiment of the present application. Figure 8 for Figure 7 FIG. 1 is an exploded view of the heat sink 120 and the power module 130 of the motor controller integrated module 100 .

[0071] In one embodiment, a motor controller integrated module 100 integrates a bus capacitor 110, a heat sink 120 and two power modules 130, such as Figure 5 and Figure 8 As shown, a bus capacitor 110 includes a shell 140 and a capacitor core package 150, a shell 140 is used to fix a heat sink 120 and two groups of power modules 130, each group of power modules 130 is used to realize the mutual conversion between direct current and a group of three-phase alternating current, a capacitor core package 150 is used to electrically connect one end of each group of power modules 130 for transmitting direct current, a capacitor core package 150 is used to output direct current to at least one group of power modules 130 or receive direct current output by at least one group of power modules 130, and a heat sink 120 is used to cool the two groups of power modules 130.

[0072] In the embodiment of the present application, a bus capacitor 110 can provide ripple current when the power supply device 15 drives the motor, reduce the bus current fluctuation of the whole vehicle, and thus reduce the bus voltage ripple of the whole vehicle. A housing 140 provides space for the installation and fixation of a heat sink 120 and two sets of power modules 130.

[0073] One group of power modules 130 is used to convert direct current into a group of three-phase alternating current, or one group of power modules 130 is used to convert a group of three-phase alternating current into one group of direct current. Two groups of power modules 130 can realize the same direction conversion or reverse conversion.

[0074] In one embodiment, a capacitor core pack 150 is used to output direct current to at least one group of power modules 130, and at least one group of power modules 130 is used to receive the direct current output by a capacitor core pack 150 and respectively convert the direct current into a group of three-phase alternating current, and transmit the three-phase alternating current to the motor 12 (such as Figure 2 The windings (shown) drive the motor 12 to run.

[0075] In one embodiment, a capacitor core package 150 is used to receive direct current output by a group of power modules 130. The generator 13 receives power provided by the engine 11, drives the rotor of the generator 13 to rotate and cuts the magnetic flux lines to generate an induced current in the winding. The current is converted into direct current through a group of power modules 130 and will be transmitted through a capacitor core package 150 to charge the power battery 30.

[0076] In one embodiment, when the generator 13 is used as a driving motor, two groups of power modules 130 are used to receive direct current through a capacitor core package 150 and convert the direct current into two groups of three-phase alternating currents to be transmitted to the generator 13 and the motor 12 respectively.

[0077] Among them, a heat sink 120 is used to cool two groups of power modules 130, which is conducive to timely heat dissipation of the two groups of power modules 130 and ensures the normal operation of the motor controller integrated module 100.

[0078] In one embodiment, a bus capacitor 110 and two groups of power modules 130 may be connected by laser welding or screwing.

[0079] In one embodiment, a housing 140 includes a receiving groove 141, such as Figure 4 and Figure 5 As shown, a receiving groove 141 is used to receive a capacitor core package 150. Figure 6As shown, the length of a capacitor core package 150 along its width direction Y is less than the length of a capacitor core package 150 along its length direction X, and the groove peripheral wall of a receiving groove 141 includes two first side walls 141a and 141b, and the two first side walls 141a and 141b are opposite to each other along the width direction Y of a capacitor core package 150. A heat sink 120 includes a heat sink 121, such as Figure 6 and Figure 7 As shown, along the width direction Y of a capacitor core package 150, two groups of power modules 130 are stacked with a heat sink 121 and arranged on one side of a first side wall 141a away from another first side wall 141b, and each group of power modules 130 includes three power modules 134, as shown in FIG. Figure 8 As shown, three power modules 134 are arranged in sequence along the length direction X of a capacitor core package 150 , and the thickness direction of each power module 134 is parallel to the width direction Y of a capacitor core package 150 .

[0080] In the embodiment of the present application, the length of a capacitor core package 150 along its width direction Y is recorded as L1, and the length of a capacitor core package 150 along its length direction X is recorded as L2. Figure 6 As shown, L1<L2, which is conducive to reducing the space occupied by a capacitor core package 150 in the motor controller integrated module 100 along its width direction Y, and is conducive to reducing the overall volume of the motor controller integrated module 100. The groove peripheral wall of a receiving groove 141 includes two first side walls 141a and 141b, and the two first side walls 141a and 141b are opposite to each other along the width direction Y of a capacitor core package 150. A capacitor core package 150 is accommodated between the two first side walls 141a and 141b, so that the length of a capacitor core package 150 along its width direction Y does not exceed the distance between the two first side walls 141a and 141b, so that the space occupied by a capacitor core package 150 along its width direction Y is small, so that the two first side walls 141a and 141b can also reduce the electrical interference of other electrical components in the motor controller integrated module 100 along the width direction Y of a capacitor core package 150 to a capacitor core package 150, which is conducive to the normal operation of the electrical components in the motor controller integrated module 100.

[0081] In the embodiment of the present application, a heat sink 120 includes a heat sink 121, such as Figure 6 and Figure 8As shown, a heat sink 121 is used to circulate coolant to dissipate heat for two groups of power modules 130. Two groups of power modules 130 and a heat sink 121 are stacked along the width direction Y of a capacitor core package 150 and arranged on the side of a first side wall 141a away from another first side wall 141b, so that two groups of power modules 130 and a heat sink 121 are more compactly arranged close to a first side wall 141a. Arranging two groups of power modules 130 and a heat sink 121 on the side with a larger length of a capacitor core package 150 is conducive to the two groups of power modules 130 and a heat sink 121 not occupying too much space of the motor controller integrated module 100 along the length direction X of a capacitor core package 150, which is conducive to improving the integration of the motor controller integrated module 100, making the motor controller integrated module 100 miniaturized, reducing the overall volume of the motor controller integrated module 100, and optimizing the layout in the vehicle. If two groups of power modules 130 and a bus capacitor 110 are laid out along the length direction X of a capacitor core package 150 or along the width direction Y of a capacitor core package 150, the overall volume of the motor controller integrated module 100 will be larger, which is not conducive to reducing the volume of the motor controller integrated module 100 and is not conducive to the miniaturized layout of the power supply device 15 in the electric vehicle 1.

[0082] In the embodiments of the present application, Figure 7 and Figure 8 As shown, a heat sink 121 and two groups of power modules 130 are stacked together, so that the heat generated by the two groups of power modules 130 can be absorbed by the heat sink 121 faster through a short circuit, and can also have a larger heat dissipation contact area, which is conducive to one heat sink 121 to dissipate heat for the two groups of power modules 130 at the same time.

[0083] In the embodiment of the present application, each group of power modules 130 includes three power modules 134, such as Figure 8 As shown, three power modules 134 are arranged in sequence along the length direction X of a capacitor core package 150, and the three power modules 134 are stacked on a capacitor core package 150 along the width direction Y of a capacitor core package 150. The thickness direction of each power module 134 is parallel to the width direction Y of a capacitor core package 150. The length of each power module 134 in the thickness direction is relatively small, and the thickness direction of each power module 134 is parallel to the width direction Y of a capacitor core package 150, so that each power module 134 does not occupy too much space of the motor controller integrated module 100 along the width direction Y of a capacitor core package 150.

[0084] In the embodiment of the present application, the motor controller integrated module 100 sets a smaller length of a capacitor core package 150 along its width direction Y so that a capacitor core package 150 occupies a smaller space of the motor controller integrated module 100 along the width direction Y of a capacitor core package 150, thereby reserving a space of a capacitor core package 150 along its width direction Y for arranging the heat sink 120 and the power module 130. Two groups of power modules 130 and a heat sink 121 are stacked and arranged on the outside of a receiving groove 141 along the width direction Y, and the thickness direction of each power module 134 is parallel to the width direction Y of a capacitor core package 150, so that the two groups of power modules 130 and a heat sink 121 are more compactly arranged on one side of a capacitor core package 150 along its width direction Y, so that the two groups of power modules 130 and a heat sink 121 do not occupy too much space of the motor controller integrated module 100 along the length direction X of a capacitor core package 150, thereby making the volume of the motor controller integrated module 100 along the width direction Y and along the length direction X of a capacitor core package 150 smaller, thereby making the overall volume of the motor controller integrated module 100 small, and thus making the volume of the power supply device 15 small, which is beneficial to the layout of the power supply device 15 in the whole vehicle.

[0085] In one embodiment, the notch 142 of a receiving groove 141 has an insulating rubber layer (not shown), so that a capacitor core package 150 is fixed in a receiving groove 141, which is beneficial to the stability of the electrical connection and also helps to prevent the capacitor core package 150 from being electrically interfered by spatial electrical components along the arrangement direction Z of the groove bottom 144 and the notch 142 of the receiving groove 141.

[0086] In one embodiment, the length of one capacitor core package 150 along its length direction X is greater than the sum of the lengths of two groups of power modules 130 and one heat sink 121 along the width direction Y of one capacitor core package 150 .

[0087] like Figure 6 As shown, in the embodiment of the present application, the length of a capacitor core package 150 along its length direction X is L2, and the sum of the lengths of two groups of power modules 130 and one heat sink 121 along the width direction Y of a capacitor core package 150 is recorded as L3, L2>L3, so that although the two groups of power modules 130 and one heat sink 121 are stacked along the width direction Y of a capacitor core package 150 and arranged on a first side wall 141a, they will not occupy too much space of the motor controller integrated module 100 along the width direction Y of a capacitor core package 150, which is beneficial to the integration of two groups of power modules 130, a heat sink 121 and a capacitor core package 150 without making the overall volume of the motor controller integrated module 100 relatively large, which is beneficial to the miniaturized layout of the motor controller integrated module 100.

[0088] In one embodiment, the length of a first side wall 141a along the length direction X of a capacitor core package 150 is greater than the spacing between the two first side walls 141a and 141b along the width direction Y of a capacitor core package 150, and the length of a first side wall 141a along the length direction X of a capacitor core package 150 is greater than the sum of the lengths of two groups of power modules 130 and a heat sink 121 along the width direction Y of a capacitor core package 150.

[0089] like Figure 6 As shown, in the embodiment of the present application, the length of a first side wall 141a along the length direction X of a capacitor core package 150 is recorded as L4, and the distance between the two first side walls 141a and 141b along the width direction Y of a capacitor core package 150 is recorded as L5, L4>L5, and the two first side walls 141a and 141b of a receiving groove 141 occupy a very small space along the width direction Y of a capacitor core package 150, which is conducive to a capacitor core package 150 between the two first side walls 141a and 141b having a smaller volume along its width direction Y.

[0090] In the embodiment of the present application, the length of a first side wall 141a along the length direction X of a capacitor core package 150 is L4, and the sum of the lengths of two groups of power modules 130 and one heat sink 121 along the width direction Y of a capacitor core package 150 is L3, L4>L3, and the two groups of power modules 130 and one heat sink 121 occupy a smaller space along the width direction Y of a capacitor core package 150, which is conducive to the miniaturized arrangement of the motor controller integrated module 100 along the width direction Y of a capacitor core package 150.

[0091] In one embodiment, along the width direction Y of a capacitor core package 150 , a capacitor core package 150 , a first side wall 141 a , a group of power modules 131 , a heat sink 121 and another group of power modules 132 are arranged in sequence.

[0092] like Figure 6 and Figure 8As shown, in the embodiment of the present application, along the width direction Y of a capacitor core package 150, a heat sink 121 is arranged between a group of power modules 131 and another group of power modules 132, so that a heat sink 121 can dissipate heat for two groups of power modules 130 at the same time, and the heat generated by the two groups of power modules 130 can also be absorbed by a heat sink 121 through a short circuit, which is conducive to improving the cooling efficiency of the two groups of power modules 130 by a heat sink 121. The stacking arrangement of a heat sink 121, a group of power modules 131 and another group of power modules 132 is also conducive to a large heat dissipation contact area between a heat sink 121 and the two groups of power modules 130, which is conducive to quickly taking away the heat generated by the two groups of power modules 130 when the coolant passes through a heat sink 121, which is conducive to ensuring the normal operation of the two groups of power modules 130.

[0093] In the embodiment of the present application, a capacitor core package 150, a first side wall 141a, a group of power modules 131, a heat sink 121 and another group of power modules 132 are arranged in sequence along the width direction Y of a capacitor core package 150, so that a capacitor core package 150, a group of power modules 131, a heat sink 121 and another group of power modules 132 will not occupy too much space of the motor controller integrated module 100 along the length direction X of a capacitor core package 150, so that the volume of the motor controller integrated module 100 along the length direction X of a capacitor core package 150 is small. In addition, the overall length of a capacitor core package 150, a first side wall 141a, a group of power modules 131, a heat sink 121 and another group of power modules 132 along the width direction Y of a capacitor core package 150 is also small, so that the overall volume of the motor controller integrated module 100 is small, which is conducive to the miniaturized layout of the motor controller integrated module 100 in the power supply device 15, thereby optimizing the layout of the entire vehicle.

[0094] In one embodiment, a heat sink 120 further includes another heat sink 122, such as Figure 6 and Figure 8 As shown, along the width direction Y of a capacitor core package 150, a capacitor core package 150, a first side wall 141a, another heat sink 122, a group of power modules 131, a heat sink 121 and another group of power modules 132 are arranged in sequence.

[0095] In an embodiment of the present application, along the width direction Y of a capacitor core package 150, a capacitor core package 150, a first side wall 141a, another heat sink 122, a group of power modules 131, a heat sink 121 and another group of power modules 132 are arranged in sequence, and the two heat sinks 121, 122 and the two groups of power modules 130 are alternately stacked, which increases the heat dissipation area between the two heat sinks 121, 122 and the two groups of power modules 130, accelerates the absorption of heat generated by the two groups of power modules 130 by the two heat sinks 121, 122, and is beneficial to improving the cooling effect of one radiator 120 on the two groups of power modules 130.

[0096] In one embodiment, a heat sink 120 further includes a base plate 123, such as Figure 6 and Figure 8 As shown, a bottom plate 123 includes two holes 124, and the two holes 124 are used to connect the internal flow channel of a heat sink 121 through the internal flow channel of the bottom plate 123. Among them, along the width direction Y of a capacitor core package 150, a bottom plate 123 is arranged on the side of two groups of power modules 130 and a heat sink 121 away from a capacitor core package 150. The opening direction of the two holes 124 is the same as the direction of the notch 142 of a receiving groove 141.

[0097] In the embodiment of the present application, a bottom plate 123 includes two holes 124, and the two holes 124 are used to receive the coolant from the external cooling circulation system and output the coolant after absorbing heat and heating in a radiator 120. The two holes 124 are used to connect the internal flow channel of a heat sink 121 through the internal flow channel of a bottom plate 123, and the internal flow channels of a heat sink 121 and a bottom plate 123 are connected through the two holes 124, so that the coolant in a radiator 120 can flow smoothly. Among them, a bottom plate 123 can also cool down a group of power modules 130 adjacent to it.

[0098] In the embodiment of the present application, along the width direction Y of a capacitor core package 150, a bottom plate 123 is arranged on the side of two groups of power modules 130 and a heat sink 121 away from a capacitor core package 150, so that a bottom plate 123 can directly cool down the other group of power modules 132 in the two groups of power modules 130. Compared with arranging a bottom plate 123 on the side of two groups of power modules 130 and a heat sink 121 close to a capacitor core package 150, arranging a bottom plate 123 on the side of two groups of power modules 130 and a heat sink 121 away from a capacitor core package 150 is conducive to shortening the distance between the electrical connection of a capacitor core package 150 and the two groups of power modules 130, and is also conducive to realizing the electrical connection of the copper busbar between a capacitor core package 150 and the two groups of power modules 130.

[0099] In the embodiment of the present application, the opening direction of the two holes 124 is the same as the direction of the notch 142 of one receiving groove 141, so that the two holes 124 on one bottom plate 123 can be aligned with the internal flow channel 15b (such as Figure 3 As shown in the figure, the motor controller integrated module 100 is connected to improve the integration level of the motor controller integrated module 100 in the power supply device 15.

[0100] Fig. 9 A schematic diagram of the structure of a housing 140 provided in an embodiment of the present application.

[0101] In one embodiment, a housing 140 further includes two fixing protrusions 143, such as Fig. 9 As shown, the two fixing protrusions 143 are used to fix the electrical components, such as Figure 5 As shown, along the width direction Y of a capacitor core package 150, two fixing protrusions 143 protrude from a first side wall 141a away from a capacitor core package 150, and the space between the two fixing protrusions 143 is used to accommodate a heat sink 120 and two sets of power modules 130. Figure 6 As shown, the distance between two fixing protrusions 143 along the length direction X of a capacitor core package 150 is greater than the length of a heat sink 120 or each group of power modules 130. The length of each fixing protrusion 143 along the width direction Y of a capacitor core package 150 is greater than the sum of the lengths of a heat sink 120 and two groups of power modules 130.

[0102] In the embodiment of the present application, two fixing protrusions 143 along the width direction Y of one capacitor core package 150 protrude from one first side wall 141a away from one capacitor core package 150, so that a heat sink 120 stacked along the width direction Y of one capacitor core package 150 and arranged on one side of one first side wall 141a away from another first side wall 141b can be fixed to the two fixing protrusions 143, which is conducive to the overall structural stability of the motor controller integrated module 100. The space between the two fixing protrusions 143 is used to accommodate a heat sink 120 and two groups of power modules 130, so that the two fixing protrusions 143 of a housing 140 and the heat sink 120 and two groups of power modules 130 are more integrated, so that the volume of a heat sink 120 and two groups of power modules 130 along the length direction X of one capacitor core package 150 will not be too large, which is conducive to the miniaturization of the motor controller integrated module 100.

[0103] Among them, Fig. 9 As shown, the two fixing protrusions 143 can also fix electrical components through the fixing through holes 143a on both sides. For example, the two fixing protrusions 143 fix the Hall copper busbar assembly (not shown) through the fixing through holes 143a on both sides, which is beneficial to improving the integration of the power supply device 15.

[0104] like Figure 6 As shown, in the embodiment of the present application, the distance between the two fixing protrusions 143 along the length direction X of a capacitor core package 150 is recorded as L6, the length of a heat sink 120 is recorded as L7, and the length of each group of power modules 130 is recorded as L8, L6>L7, L6>L8, and the arrangement space of a heat sink 120 and two groups of power modules 130 along the length direction X of a capacitor core package 150 is small, so that the volume of the motor controller integrated module 100 along the length direction X of a capacitor core package 150 is small, which is conducive to the miniaturized arrangement of the motor controller integrated module 100.

[0105] like Figure 6 As shown, in the embodiment of the present application, the length of each fixed protrusion 143 along the width direction Y of a capacitor core package 150 is recorded as L9, and the sum of the lengths of a heat sink 120 and two groups of power modules 130 is recorded as L10, L9>L10, so that along the width direction Y of a capacitor core package 150, a heat sink 120 and two groups of power modules 130 are arranged in a shell 140 of a motor controller integrated module 100, and will not occupy too much space outside a shell 140, which is conducive to the small volume arrangement of the motor controller integrated module 100 along the width direction Y of a capacitor core package 150.

[0106] Fig.10 A schematic diagram of the structure of the power module 134 provided in an embodiment of the present application.

[0107] In one embodiment, each power module 134 includes two input copper bars 1340 and one output copper bar 1343. Figure 6 and Fig.10 As shown, two input copper bars 1340 are used to electrically connect a capacitor core package 150 to receive direct current, and an output copper bar 1343 is used to output one-phase alternating current. In which, along the arrangement direction Z of the bottom 144 and the notch 142 of a receiving slot 141, the two input copper bars 1340 and the output copper bar 1343 are arranged opposite to each other, as shown in FIG. Figure 6 As shown, the two input copper bars 1340 are on the same side as the notch 142 of a receiving slot 141, and the two input copper bars 1340 of each power module 134 are arranged at intervals along the length direction X of a capacitor core package 150, as shown in FIG. Figure 6 and Figure 8 As shown, each input copper bar 1340 is bent along the width direction Y of a capacitor core package 150 toward a first side wall 141a.

[0108] In the embodiment of the present application, each power module 134 includes two input copper bars 1340 and one output copper bar 1343, the two input copper bars 1340 are used to electrically connect a capacitor core package 150 to receive direct current, and one output copper bar 1343 is used to output one-phase alternating current, and each group of power modules 130 includes three power modules 134. The three power modules 134 are used to receive the direct current output by a capacitor core package 150 and are respectively used to convert the direct current into a group of three-phase alternating current, and then transmit the three-phase alternating current to the winding of the motor 12 to drive the motor 12 to run. Or the three power modules 134 convert the three-phase alternating current output by the generator 13 into direct current, and charge the power battery 30 through a capacitor core package 150.

[0109] In the embodiment of the present application, along the arrangement direction Z of the bottom 144 and the notch 142 of a receiving slot 141, two input copper bars 1340 and an output copper bar 1343 are arranged relative to each other, so that the current in each power module 134 can be transmitted along the arrangement direction Z of the bottom 144 and the notch 142 of a receiving slot 141. The two input copper bars 1340 and the notch 142 of a receiving slot 141 are on the same side, which is conducive to the transmission of direct current between the two input copper bars 1340 of each power module 134 and a capacitor core package 150. The two input copper bars 1340 of each power module 134 are arranged at intervals along the length direction X of a capacitor core package 150 to avoid electrical connection interference between the two input copper bars 1340 of each power module 134. Each input copper busbar 1340 is bent along the width direction Y of a capacitor core package 150 toward a first side wall 141a, which is beneficial for electrically connecting each input copper busbar 1340 with a capacitor core package 150 on the other side of a first side wall 141a, and ensures that each power module 134 does not occupy too much space of the motor controller integrated module along the arrangement direction Z of the groove bottom 144 and the groove opening 142 of a receiving groove 141.

[0110] Fig.11 An exploded view of two input connection copper sheets 152 and an insulating partition 157 provided in an embodiment of the present application.

[0111] In one embodiment, a bus capacitor 110 further includes two input connection copper sheets 152, such as Figure 4 , Fig.10 and Fig.11As shown, an input connection copper sheet 152a is used to electrically connect the positive electrode of a capacitor core package 150 and an input copper bar 1341 of each power module 134, and another input connection copper sheet 152b is used to electrically connect the negative electrode of a capacitor core package 150 and another input copper bar 1342 of each power module 134. In which, along the arrangement direction Z of the groove bottom 144 and the notch 142 of a receiving groove 141, the two input connection copper sheets 152 are stacked and insulated. Along the arrangement direction Z of the groove bottom 144 and the notch 142 of a receiving groove 141, the two input connection copper sheets 152 are stacked on the two input copper bars 1340 of each power module 134.

[0112] In the embodiment of the present application, an input connecting copper sheet 152a is used to electrically connect the positive electrode of a capacitor core package 150 and an input copper bar 1341 of each power module 134, and the input copper bar 1341 is the positive electrode of each power module 134. Another input connecting copper sheet 152b is used to electrically connect the negative electrode of a capacitor core package 150 and another input copper bar 1342 of each power module 134, and the other input copper bar 1342 is the negative electrode of each power module 134. The positive and negative electrodes of a capacitor core package 150 are electrically connected to the positive and negative electrodes of each power module 134 through two input connecting copper sheets 152 of a bus capacitor 110, so that the direct current of a capacitor core package 150 can be input into the power module 134, so that each power module 134 can output a phase of alternating current to the winding of the motor 12 through an output copper bar 1343. The positive and negative electrodes of a capacitor core package 150 are electrically connected to the positive and negative electrodes of a power module 134 respectively through two input connecting copper sheets 152 of a bus capacitor 110, and the power module 134 can also output direct current to charge the power battery.

[0113] In an embodiment of the present application, along the arrangement direction Z of the groove bottom 144 and the groove opening 142 of a receiving groove 141, two input connecting copper sheets 152 are stacked and insulated, and the two input connecting copper sheets 152 are stacked, one input connecting copper sheet 152a is connected to the positive pole of a capacitor core package 150, and the other input connecting copper sheet 152b is connected to the negative pole of a capacitor core package 150, so that the current directions of the two input connecting copper sheets 152 are opposite. When the two input connecting copper sheets 152 are stacked, the magnetic fields generated by the two input connecting copper sheets 152 with opposite current directions can offset each other to a part, thereby reducing the inductance generated by the two input connecting copper sheets 152, so that a bus capacitor 110 is suitable for application in the motor controller integrated module 100.

[0114] In one embodiment, the insulation interval between the two input connection copper sheets 152 can be achieved by inserting an insulation partition 157 between the two input connection copper sheets 152. Alternatively, the insulation interval between the two input connection copper sheets 152 can be achieved by injecting insulation material or potting insulation glue between the two input connection copper sheets 152.

[0115] In an embodiment of the present application, along the arrangement direction Z of the groove bottom 144 and the groove opening 142 of a receiving groove 141, two input connecting copper sheets 152 are stacked on the two input copper bars 1340 of each power module 134, so that the two input connecting copper sheets 152 can be electrically connected to the two input copper bars 1340 of each power module 134. The stacked arrangement is also beneficial for making the electrical connection more stable, improving the integration of the motor controller integrated module 100, and reducing the volume occupied by the tiling, which is beneficial for the miniaturized layout of the motor controller integrated module 100.

[0116] In one embodiment, a bus capacitor 110 further includes two input connection copper sheets 153a, 153b. Fig.10 and Fig.11 As shown, two input connecting copper sheets 152 are electrically connected to the positive and negative electrodes of a busbar capacitor 110 through another two input connecting copper sheets 153a and 153b. Along the arrangement direction Z of the bottom 144 and the notch 142 of a receiving groove 141, a capacitor core package 150 is stacked between the other two input connecting copper sheets 153a and 153b.

[0117] In the embodiment of the present application, the positive electrode of one capacitor core package 150 is electrically connected to one 153a of the other two input connection copper sheets 153a and 153b, one 153a of the other two input connection copper sheets 153a and 153b is electrically connected to one input connection copper sheet 152a, and one input connection copper sheet 152a is electrically connected to one input copper bar 1341 of each power module 134. The negative electrode of one capacitor core package 150 is electrically connected to the other 153b of the other two input connection copper sheets 153a and 153b, the other 153b of the other two input connection copper sheets 153a and 153b is electrically connected to another input connection copper sheet 152b, and the other input connection copper sheet 152b is electrically connected to another input copper bar 1342 of each power module 134.

[0118] In the embodiment of the present application, along the arrangement direction Z of the groove bottom 144 and the notch 142 of a receiving groove 141, a capacitor core package 150 is stacked and arranged between the other two input connection copper sheets 153a and 153b, so that the positive and negative electrodes of a capacitor core package 150 can be respectively contacted with the other two input connection copper sheets 153a and 153b to achieve electrical connection. One of the other two input connection copper sheets 153a and 153b is connected to the positive electrode of a capacitor core package 150, and the other input connection copper sheet 153b of the other two input connection copper sheets 153a and 153b is connected to the negative electrode of a capacitor core package 150.

[0119] In one embodiment, if Fig.11 As shown, the other two input connection copper sheets 153a and 153b are respectively integrated with the two input connection copper sheets 152. The specific shapes of the other two input connection copper sheets 153a and 153b are related to the arrangement of a capacitor core package 150 in a receiving groove 141.

[0120] In one embodiment, the three power modules 134 in the two groups of power modules 130 are aligned along the width direction Y of a capacitor core package 150, such as Figure 3 , Figure 8 and Fig.11 As shown, each input connection copper sheet 152 includes three pairs of connection holes 154 and three pairs of avoidance holes 155. Two connection holes 154a in each pair of connection holes 154 of an input connection copper sheet 152a are respectively used to connect one input copper bar 1341 of two power modules 134 aligned along the width direction Y of one capacitor core package 150, and two avoidance holes 155a in each pair of avoidance holes 155 of an input connection copper sheet 152a are respectively used to pass through the connector connecting a pair of connection holes 154 of another input connection copper sheet 152b and another input copper bar 1342 of two power modules 134. Among them, the three pairs of connection holes 154 and the three pairs of avoidance holes 155 in each input connection copper sheet 152 are alternately arranged in sequence along the length direction X of one capacitor core package 150. Along the arrangement direction Z of the groove bottom 144 and the groove opening 142 of one receiving groove 141 , the three pairs of connection holes 154 of one input connection copper sheet 152 a are respectively aligned with the three pairs of avoidance holes 155 of another input connection copper sheet 152 b .

[0121] In the embodiment of the present application, the three power modules 134 in the two groups of power modules 130 are aligned along the width direction Y of one capacitor core package 150, which is conducive to reducing the space occupied by the two groups of power modules 130 in the length direction X of one capacitor core package 150. Each input connection copper sheet 152 includes three pairs of connection holes 154 and three pairs of avoidance holes 155, so that each input connection copper sheet 152 can be electrically connected to the positive electrode or negative electrode of each group of power modules 130 respectively.

[0122] In an embodiment of the present application, two connection holes 154a in each pair of connection holes 154 of an input connection copper sheet 152a are respectively used to connect an input copper busbar 1341 of two power modules 134 aligned along the width direction Y of a capacitor core package 150, and two avoidance holes 155a in each pair of avoidance holes 155 of an input connection copper sheet 152a are respectively used to pass through a pair of connection holes 154 connecting another input connection copper sheet 152b and a connector of another input copper busbar 1342 of two power modules 134, so that an input connection copper sheet 152a can be electrically connected to two groups of power modules 130 stacked along the width direction Y of a capacitor core package 150 at the same time, and sharing one input connection copper sheet 152a and another input connection copper sheet 152b can improve the integration of the motor controller integrated module 100. It is also possible that each pair of connection holes 154 of an input connecting copper sheet 152a, when electrically connected to an input copper busbar 1341 of two power modules 134 aligned along the width direction Y of a capacitor core package 150, is not electrically interfered by a pair of connection holes 154 of another input connecting copper sheet 152b connected to another input copper busbar 1342 of the two power modules 134.

[0123] like Figure 8 and Fig.11 As shown, in an embodiment of the present application, three pairs of connection holes 154 and three pairs of avoidance holes 155 in each input connecting copper sheet 152 are arranged alternately in sequence along the length direction X of a capacitor core package 150, and each group of power modules 130 includes three power modules 134, and the three power modules 134 are arranged alternately in sequence along the length direction X of a capacitor core package 150, so that the three pairs of connection holes 154 and three pairs of avoidance holes 155 of each input connecting copper sheet 152 are stacked and connected with one input copper bus 1341 and another input copper bus 1342 of the three power modules 134 of each group of power modules 130 in a one-to-one correspondence.

[0124] In the embodiment of the present application, along the arrangement direction Z of the groove bottom 144 and the notch 142 of a receiving groove 141, the three pairs of connection holes 154 of an input connection copper sheet 152a are respectively aligned with the three pairs of avoidance holes 155 of another input connection copper sheet 152b, so that when the three pairs of connection holes 154 of an input connection copper sheet 152a are electrically connected to an input copper bar 1341 of each power module 134, they will not be electrically interfered by the other input connection copper sheet 152b. Similarly, the three pairs of avoidance holes 155 of an input connection copper sheet 152a are aligned with the three pairs of connection holes 154 of another input connection copper sheet 152b, so that when the three pairs of connection holes 154 of another input connection copper sheet 152b are electrically connected to another input copper bar 1342 of each power module 134, they will not be electrically interfered by the one input connection copper sheet 152a.

[0125] like Fig.11 As shown, in one embodiment, two connection holes 154a in each pair of connection holes 154 are arranged along the width direction Y of a capacitor core package 150, and two avoidance holes 155a in a pair of avoidance holes 155 are arranged along the width direction Y of a capacitor core package 150. In which, along the arrangement direction Z of the groove bottom 144 and the groove opening 142 of a receiving groove 141, each avoidance hole 155a is aligned with a connection hole 154a. The aperture of each avoidance hole 155a is larger than the aperture of a connection hole 154a aligned with it.

[0126] like Figure 8 and Fig.11 As shown, in the embodiment of the present application, two connection holes 154a in each pair of connection holes 154 are arranged along the width direction Y of a capacitor core package 150, so that one input copper bar 1341 of two power modules 134 aligned along the width direction Y of a capacitor core package 150 can be aligned along the width direction Y of a capacitor core package 150, and two avoidance holes 155a in a pair of avoidance holes 155 are arranged along the width direction Y of a capacitor core package 150, so that another input copper bar 1342 of two power modules 134 aligned along the width direction Y of a capacitor core package 150 can be aligned along the width direction Y of a capacitor core package 150. It is beneficial for the two input connection copper sheets 152 to be electrically connected to the two groups of power modules 130 stacked and arranged along the width direction Y of a capacitor core package 150.

[0127] In the embodiment of the present application, along the arrangement direction Z of the groove bottom 144 and the groove opening 142 of a receiving groove 141, each avoidance hole 155a is aligned with a connecting hole 154a, so that the two avoidance holes 155a in each pair of avoidance holes 155 of an input connecting copper sheet 152a respectively pass through the connecting pieces of a pair of connecting holes 154 connecting another input connecting copper sheet 152b and another input copper busbar 1342 of the two power modules 134 more smoothly.

[0128] In the embodiment of the present application, the aperture of each avoidance hole 155a is larger than the aperture of a connection hole 154a aligned therewith, so as to facilitate the insertion of the insulating partition 157 from each avoidance hole 155a and avoid electrical connection between the two input connection copper sheets 152.

[0129] In one embodiment, if Fig.11 As shown, two avoidance holes 155a in a pair of avoidance holes 155 arranged along the width direction Y of a capacitor core package 150 can be connected to each other to form a groove 158, which is beneficial to saving copper sheet materials.

[0130] Fig.12Another structural schematic diagram of the motor controller integrated module 100 provided in an embodiment of the present application.

[0131] In one embodiment, an output copper bar 1343 of each power module 134 is bent along a width direction Y of a capacitor core package 150 toward a first side wall 141a, such as Fig.10 and Fig.12 As shown, the motor controller integrated module 100 also includes two groups of output connection copper sheets 156, one group of output connection copper sheets is marked as 156a, and the other group of output connection copper sheets is marked as 156b. Each group of output connection copper sheets 156 includes three output connection copper sheets 1561. The three output connection copper sheets 1561 of each group of output connection copper sheets 156 are respectively used to connect one output copper bus 1343 of the three power modules 134 of each group of power modules 130. Figure 8 and Fig.12 As shown, along the arrangement direction Z of the groove bottom 144 and the notch 142 of a receiving groove 141, the three output connection copper sheets 1561 of each group of output connection copper sheets 156 are arranged on the same side as an output copper bar 1343 of each power module 134 and are stacked on two groups of power modules 130 and a heat sink 120. Along the width direction Y of a capacitor core package 150, the three output connection copper sheets 1561 of each group of output connection copper sheets 156 extend away from a first side wall 141a. Along the length direction X of a capacitor core package 150, the three output connection copper sheets 1561 of one group of output connection copper sheets 156a and the three output connection copper sheets 1561 of another group of output connection copper sheets 156b are arranged alternately in sequence.

[0132] In the embodiment of the present application, an output copper bar 1343 of each power module 134 is bent toward a first side wall 141a along the width direction Y of a capacitor core package 150, which is conducive to reducing the space occupied by an output copper bar 1343 of each power module 134 along the arrangement direction Z of the groove bottom 144 and the groove opening 142 of a receiving groove 141. The two groups of output connection copper sheets 156 are used to output or input the three-phase AC generated by the three power modules 134 of the two groups of power modules 130.

[0133] In the embodiment of the present application, along the arrangement direction Z of the groove bottom 144 and the notch 142 of a receiving groove 141, the three output connection copper sheets 1561 of each group of output connection copper sheets 156 are arranged on the same side as an output copper bar 1343 of each power module 134, which is conducive to smoothly outputting the alternating current output by an output copper bar 1343 of each power module 134 from the three output connection copper sheets 1561 to the motor controller integrated module 100 through a short circuit. Each group of output connection copper sheets 156 is stacked on two groups of power modules 130 and a heat sink 120, which is conducive to the electrical connection of each group of output connection copper sheets 156 with an output copper bar 1343 of each power module 134, and is also conducive to reducing the space occupied by each group of output connection copper sheets 156 in the width direction Y of a capacitor core package 150 and the length direction X of a capacitor core package 150.

[0134] In the embodiment of the present application, the three output connecting copper plates 1561 of each group of output connecting copper plates 156 extend back to a first side wall 141a along the width direction Y of a capacitor core package 150, which is beneficial for the three output connecting copper plates 1561 of each group of output connecting copper plates 156 to output the alternating current in the motor controller integrated module 100 to the Hall copper busbar assembly and the winding of the motor 12.

[0135] In the embodiment of the present application, three output connecting copper sheets 1561 of one group of output connecting copper sheets 156a and three output connecting copper sheets 1561 of another group of output connecting copper sheets 156b are arranged alternately in sequence along the length direction X of a capacitor core package 150, which is beneficial to simplify the connection arrangement of the two groups of output connecting copper sheets 156 and one output copper bus 1343 of each power module 134 of the two groups of power modules 130, and is also beneficial to shorten the connection path of the two groups of output connecting copper sheets 156 and one output copper bus 1343 of each power module 134 of the two groups of power modules 130, thereby saving copper bus material.

[0136] like Figure 8 and Fig.12 As shown, in one embodiment, along the length direction X of a capacitor core package 150, three output connecting copper sheets 1561 of a group of output connecting copper sheets 156a and three output connecting copper sheets 1561 of another group of output connecting copper sheets 156b are arranged flat, wherein the three output connecting copper sheets 1561 of another group of output connecting copper sheets 156b are bent and arranged to match the design of two groups of power modules 130 being stacked along the width direction Y of a capacitor core package 150.

[0137] like Figure 8 and Fig.10As shown, in one embodiment, each power module 134 also includes a plurality of signal plug-in connectors 1344, and the plurality of signal plug-in connectors 1344 are used to realize the electrical connection of each power module 134 in the motor controller integrated module 100, and the signal plug-in connectors 1344 are arranged on the same side as an output copper bus 1343 of each power module 134.

[0138] like Figure 8 and Fig.12 As shown, in one embodiment, the motor controller integrated module 100 also includes a plurality of power module supports 135, each power module support 135 is used to fix a power module 134 to a housing 140 of the motor controller integrated module 100, so that each power module 134 of the two groups of power modules 130 can be stacked and arranged separately and fixed in position, which is beneficial to improving the stability of the motor controller integrated module 100.

[0139] In one embodiment, the motor controller integrated module 100 further integrates a circuit board 160, such as Figure 5 As shown, a housing 140 is used to fix a circuit board 160. Figure 5 and Figure 8 As shown, along the arrangement direction Z of the groove bottom 144 and the groove opening 142 of a receiving groove 141, a circuit board 160 is stacked on a housing 140, a heat sink 120 and each power module 134, and a circuit board 160, a groove bottom 144 of a receiving groove 141 and a capacitor core package 150 are arranged in sequence.

[0140] In an embodiment of the present application, a housing 140 is used to fix a circuit board 160, and a circuit board 160 is supported by a housing 140, so that the fixing stability of a circuit board 160 and a housing 140 is high, so that the overall structural strength of the motor controller integrated module 100 is stronger, and the electrical connection can also be made more stable. When the external environment applies external force to the motor controller integrated module 100, a circuit board 160 and a housing 140 will not easily undergo relative displacement, which is conducive to the motor controller integrated module 100 working in a stable state. A circuit board 160 is used to carry the electrical components of the motor controller integrated module 100, so that the electrical components are more stably arranged in the motor controller integrated module 100.

[0141] In an embodiment of the present application, along the arrangement direction Z of the groove bottom 144 and the notch 142 of a receiving groove 141, a circuit board 160 is stacked on a housing 140, a heat sink 120 and each power module 134, a circuit board 160, a groove bottom 144 of a receiving groove 141 and a capacitor core package 150 are arranged in sequence, and a circuit board 160 is located on the outer side of the groove bottom 144 of a receiving groove 141 of a housing 140, so that each power module 134 is plugged into a circuit board 160 through a signal plug wire 1344 to achieve electrical connection.

[0142] In one embodiment, the motor controller integrated module 100 further integrates an EMC filter 170. The EMC filter 170 and a bus capacitor 110 are used to filter and stabilize the DC power. Figure 6 As shown, the groove peripheral wall of a receiving groove 141 also includes two second side walls 141c and 141d, and the two second side walls 141c and 141d are arranged relatively along the length direction X of a capacitor core package 150. A capacitor core package 150 includes two groups of capacitor cores 151a and 151b. Along the length direction X of a capacitor core package 150, a second side wall 141c, a group of capacitor cores 151a, another group of capacitor cores 151b and another second side wall 141d are arranged in sequence. Among them, along the width direction Y of a capacitor core package 150, the length of one group of capacitor cores 151a is greater than the length of the other group of capacitor cores 151b. Along the width direction Y of a capacitor core package 150, a portion of another first side wall 1411 opposite to another group of capacitor cores 151b is recessed toward another group of capacitor cores 151b compared to another portion of another first side wall 1412 opposite to a group of capacitor cores 151a, and a portion of the other first side wall 1411 away from the space of another group of capacitor cores 151b is used to accommodate an EMC filter 170.

[0143] In the embodiment of the present application, an EMC filter 170 can eliminate differential mode interference and common mode interference in the current signal and reduce harmonic interference in the current signal. An EMC filter 170 and a bus capacitor 110 are used to filter and stabilize the DC power, so that the motor controller integrated module 100 can transmit accurate electrical signals to the windings of the motor 12 to drive the motor 12 to operate.

[0144] In the embodiment of the present application, the groove wall of a receiving groove 141 also includes two second side walls 141c and 141d, and the two second side walls 141c and 141d are arranged relatively along the length direction X of a capacitor core package 150. A capacitor core package 150 includes two groups of capacitor cores 151a and 151b. Along the length direction X of a capacitor core package 150, a second side wall 141c, a group of capacitor cores 151a, another group of capacitor cores 151b and another second side wall 141d are arranged in sequence. Along the length direction X of a capacitor core package 150, the two second side walls 141c and 141d electrically shield the two groups of capacitor cores 151a and 151b from other electrical components in the motor controller integrated module 100, which is conducive to the normal operation of the two groups of capacitor cores 151a and 151b.

[0145] In the embodiment of the present application, along the width direction Y of a capacitor core package 150, the length of a group of capacitor cores 151a is recorded as L11, and the length of another group of capacitor cores 151b is recorded as L12, L11>L12, so that an EMC filter 170 has space to be integrated on the motor controller integrated module 100, which is conducive to improving the integration of the power supply device 15. In one embodiment, the two groups of capacitor cores 151a and 151b are placed horizontally along the width direction Y of a capacitor core package 150. In another embodiment, the two groups of capacitor cores 151a and 151b are placed vertically along the width direction Y of a capacitor core package 150. It is only necessary to satisfy L11>L12 so that an EMC filter 170 has enough space to be integrated in the motor controller integrated module 100.

[0146] In the embodiment of the present application, along the width direction Y of a capacitor core package 150, a portion of another first side wall 1411 opposite to another group of capacitor cores 151b is recessed toward the other group of capacitor cores 151b compared to another portion of another first side wall 1412 opposite to a group of capacitor cores 151a, and a portion of the other first side wall 1411 away from the space of the other group of capacitor cores 151b is used to accommodate an EMC filter 170, which is conducive to making full use of the space on the motor controller integrated module 100 to integrate an EMC filter 170, and is conducive to improving the integration of the motor controller integrated module 100.

[0147] In one embodiment, the motor controller integrated module 100 further integrates a communication connector mounting hole 180, such as Figure 4 and Figure 5 As shown, the communication connector mounting hole 180 is used to fix the vehicle controller in the power supply device 15 for connecting the communication connector 181 of the vehicle load, and the vehicle controller is used to send a control signal to the power supply device 15 to optimize the energy distribution and operation of the vehicle.

[0148] The motor controller integrated module, power supply device and electric vehicle provided in the embodiments of the present application are introduced in detail above. Specific examples are used in this article to illustrate the principles and embodiments of the present application. The description of the above embodiments is only used to help understand the method of the present application and its core idea; at the same time, for general technical personnel in this field, according to the ideas of the present application, there will be changes in the specific embodiments and application scope. In summary, the content of this specification should not be understood as a limitation on the present application.

Claims

1. A motor controller integrated module, characterized in that: The motor controller integrated module integrates a bus capacitor, a heat sink and two groups of power modules, the bus capacitor includes a shell and a capacitor core package, the shell is used to fix the heat sink and the two groups of power modules, each group of power modules is used to realize the mutual conversion between direct current and a group of three-phase alternating current, the capacitor core package is used to electrically connect one end of each group of power modules for transmitting the direct current, and the heat sink is used to cool the two groups of power modules, wherein: The housing comprises a receiving groove, the receiving groove is used to receive the capacitor core package, the length of the capacitor core package along its width direction is less than the length of the capacitor core package along its length direction, and the groove peripheral wall of the receiving groove comprises two first side walls, and the two first side walls are opposite to each other along the width direction of the capacitor core package; The radiator includes a heat sink, and the two groups of power modules are stacked with the heat sink along the width direction of the capacitor core package and arranged on the side of one first side wall away from the other first side wall. Each group of power modules includes three power modules, and the three power modules are arranged in sequence along the length direction of the capacitor core package, and the thickness direction of each power module is parallel to the width direction of the capacitor core package.

2. The motor controller integrated module according to claim 1, characterized in that: The length of the capacitor core package along its length direction is greater than the sum of the lengths of the two groups of power modules and the heat sink along the width direction of the capacitor core package.

3. The motor controller integrated module according to claim 1, characterized in that: The length of the first side wall along the length direction of the capacitor core package is greater than the spacing between the two first side walls along the width direction of the capacitor core package, and the length of the first side wall along the length direction of the capacitor core package is greater than the sum of the lengths of the two groups of power modules and the heat sink along the width direction of the capacitor core package.

4. The motor controller integrated module according to claim 1, characterized in that: Along the width direction of the capacitor core package, the capacitor core package, the first side wall, a group of power modules, the heat sink and another group of power modules are arranged in sequence.

5. The motor controller integrated module according to claim 1, characterized in that: The one heat sink further comprises a bottom plate, the one bottom plate comprises two holes, the two holes are used to communicate with the internal flow channel of the one heat sink through the internal flow channel of the one bottom plate, wherein: Along the width direction of the capacitor core package, the bottom plate is arranged on a side of the two groups of power modules and the heat sink away from the capacitor core package; The opening directions of the two holes are the same as the notch direction of the one receiving groove.

6. The motor controller integrated module according to any one of claims 1 to 5, characterized in that: The housing further comprises two fixing protrusions, the two fixing protrusions are used to fix electrical components, the two fixing protrusions are away from the capacitor core package protrusion from the first side wall along the width direction of the capacitor core package, and the space between the two fixing protrusions is used to accommodate the heat sink and the two groups of power modules, wherein: The distance between the two fixing protrusions along the length direction of the capacitor core package is greater than the length of the heat sink or each group of power modules; The length of each of the fixing protrusions along the width direction of the capacitor core package is greater than the sum of the lengths of the heat sink and the two groups of power modules.

7. The motor controller integrated module according to any one of claims 1 to 5, characterized in that: Each of the power modules comprises two input copper bars and one output copper bar, wherein the two input copper bars are used to electrically connect the one capacitor core package to receive direct current, and the one output copper bar is used to output one-phase alternating current, wherein: Along the arrangement direction of the bottom and the notch of the receiving slot, the two input copper bars are arranged opposite to the output copper bar, the two input copper bars are on the same side as the notch of the receiving slot, the two input copper bars of each power module are arranged at intervals along the length direction of the capacitor core package, and each input copper bar is bent toward the first side wall along the width direction of the capacitor core package.

8. The motor controller integrated module according to claim 7, characterized in that: The busbar capacitor further comprises two input connecting copper sheets, one of which is used to electrically connect the positive electrode of the capacitor core package and one of the input copper bars of each of the power modules, and the other of which is used to electrically connect the negative electrode of the capacitor core package and another of the input copper bars of each of the power modules, wherein: Along the arrangement direction of the groove bottom and the groove opening of the one receiving groove, the two input connection copper sheets are stacked and arranged with insulation intervals; Along the arrangement direction of the groove bottom and the groove opening of the one receiving groove, the two input connecting copper sheets are stacked on the two input copper bars of each of the power modules.

9. The motor controller integrated module according to claim 8, characterized in that: The three power modules in the two groups of power modules are aligned respectively along the width direction of the one capacitor core package, each of the input connecting copper sheets comprises three pairs of connecting holes and three pairs of avoiding holes, the two connecting holes in each pair of connecting holes of one input connecting copper sheet are respectively used to connect one input copper bar of the two power modules aligned along the width direction of the one capacitor core package, and the two avoiding holes in each pair of avoiding holes of one input connecting copper sheet are respectively used to pass through a pair of connecting holes of another input connecting copper sheet and a connector of another input copper bar of the two power modules, wherein: The three pairs of connection holes and the three pairs of avoidance holes in each of the input connection copper sheets are arranged alternately in sequence along the length direction of the one capacitor core package; Along the arrangement direction of the groove bottom and the groove opening of the one receiving groove, the three pairs of connection holes of the one input connecting copper sheet are respectively aligned with the three pairs of avoidance holes of the other input connecting copper sheet.

10. The motor controller integrated module according to claim 9, characterized in that: The two connection holes in each pair of the connection holes are arranged along the width direction of the one capacitor core package, and the two avoidance holes in the pair of avoidance holes are arranged along the width direction of the one capacitor core package, wherein: Along the arrangement direction of the groove bottom and the groove opening of the receiving groove, each of the avoidance holes is aligned with one of the connecting holes; The diameter of each of the avoidance holes is larger than the diameter of the connection hole aligned therewith.

11. The motor controller integrated module according to claim 7, characterized in that: The output copper bar of each power module is bent along the width direction of the capacitor core package toward the first side wall, and the motor controller integrated module also includes two groups of output connection copper sheets, each group of the output connection copper sheets includes three output connection copper sheets, and the three output connection copper sheets of each group of the output connection copper sheets are respectively used to connect the output copper bar of the three power modules of each group of the power modules, wherein: Along the arrangement direction of the bottom and the notch of the one receiving groove, the three output connecting copper sheets of each group of the output connecting copper sheets are arranged on the same side as the one output copper bar of each power module and are stacked on the two groups of power modules and the one heat sink; The three output connection copper sheets of each group of the output connection copper sheets extend away from the first side wall along the width direction of the capacitor core package; The three output connecting copper sheets of one group of the output connecting copper sheets and the three output connecting copper sheets of another group of the output connecting copper sheets are arranged alternately in sequence along the length direction of the capacitor core package.

12. The motor controller integrated module according to any one of claims 1 to 5, characterized in that: The motor controller integrated module further integrates a circuit board, and the housing is used to fix the circuit board, wherein: Along the arrangement direction of the bottom and the notch of the receiving groove, the circuit board is stacked on the shell, the heat sink and each of the power modules, and the circuit board, the bottom of the receiving groove and the capacitor core package are arranged in sequence.

13. The motor controller integrated module according to any one of claims 1 to 5, characterized in that: The motor controller integrated module further integrates an EMC filter, and the EMC filter and the bus capacitor are used to filter and stabilize the DC power. The slot peripheral wall of the receiving slot also includes two second side walls, and the two second side walls are arranged relatively along the length direction of the capacitor core package. The capacitor core package includes two groups of capacitor cores, and along the length direction of the capacitor core package, one second side wall, one group of capacitor cores, another group of capacitor cores and another second side wall are arranged in sequence, wherein: Along the width direction of the one capacitor core package, the length of the one group of capacitor cores is greater than the length of the other group of capacitor cores; Along the width direction of the one capacitor core package, a portion of the other first side wall opposite to the other group of capacitor cores is recessed toward the other group of capacitor cores compared to another portion of the other first side wall opposite to the one group of capacitor cores, and the space of the portion of the other first side wall away from the other group of capacitor cores is used to accommodate the one EMC filter.

14. A power supply device, characterized in that: The power supply device comprises a housing and a motor controller integrated module as described in any one of claims 1 to 13, wherein an internal flow channel of the housing is used to connect to an internal flow channel of the heat sink in the motor controller integrated module.

15. An electric vehicle, characterized in that: The electric vehicle includes a frame, a power battery and a power supply device as described in claim 14, wherein the frame is used to fix the power battery and the power supply device, the bus capacitor in the motor controller integrated module of the power supply device is used to electrically connect the power battery, and the power battery is used to drive the wheels of the electric vehicle through a motor.

Images