Electric drive copper bar structure, electric drive controller and automobile

Abstract

The utility model discloses an electric drive copper bar structure, an electric drive controller and an automobile. The electric drive copper bar structure comprises a copper bar assembly, a circuit board and a Hall chip. The copper bar assembly comprises a connecting part and a copper bar. The connecting part is connected with the copper bar and the circuit board. The Hall chip is connected with the circuit board and is arranged close to the copper bar; a magnetic field is generated when current flows through the copper bar, and the Hall chip detects the current on the copper bar according to the magnetic field acting on the Hall chip. The Hall chip is used for detecting the current on the copper bar, and has the advantages of high precision, quick response, strong anti-interference capability and the like. The circuit board is directly connected with the connecting part of the copper bar assembly and is not shielded by other components, so that heat dissipation during working of the copper bar assembly, the circuit board and the Hall chip is facilitated, and the influence of over-high temperature on energy efficiency, service life and the like of other components in the copper bar assembly, the circuit board, the Hall chip and the electric drive controller is avoided. In addition, the device has the advantages of being small in occupied space and saving space.

Description

Technical Field

[0001] The utility model relates to the technical field of automobile accessories, in particular to an electric drive copper busbar structure, an electric drive controller and an automobile. Background Art

[0002] The Electric Drive Controller is one of the key components in electric vehicles (EV) and hybrid electric vehicles (HEV). It is responsible for controlling the operation of the motor to achieve the power output and energy recovery of the vehicle. The copper busbar assembly in the electric drive controller mainly plays the role of connection and conduction. In order to achieve precise control, it is necessary to monitor the current during the operation of the copper busbar assembly. To monitor the current size of the copper busbar assembly in the electric drive controller during operation, the copper busbar assembly needs to be connected to a current sensor.

[0003] In the prior art, when the copper busbar assembly is connected to the current sensor, the copper busbar assembly is connected to the current sensor, and the sensor housing of the copper busbar assembly and the current sensor is then connected to the housing of the electric drive controller by installing fasteners such as screws. This connection method has the disadvantages of occupying a large space and having poor heat dissipation. Utility Model Content

[0004] One of the purposes of the utility model is to provide an electric drive copper busbar structure to solve the problem that the copper busbar assembly in the prior art occupies a large space and has poor heat dissipation after being connected to the current sensor; the second purpose is to provide an electric drive controller; the third purpose is to provide a vehicle.

[0005] In order to achieve the above purpose, the technical solution adopted by the utility model is as follows:

[0006] An electrically driven copper busbar structure comprises a copper busbar assembly, a circuit board and a Hall chip; the copper busbar assembly comprises a connecting portion and a copper busbar, the connecting portion is respectively connected to the copper busbar and the circuit board; the Hall chip is connected to the circuit board and is arranged close to the copper busbar; a magnetic field is generated when current flows through the copper busbar, and the Hall chip detects the current on the copper busbar according to the magnetic field acting thereon.

[0007] According to the above-mentioned technical means, the use of Hall chip to detect the current on the copper bar has the advantages of high precision, fast response and strong anti-interference ability. The circuit board is directly connected to the connecting portion of the copper bar assembly, without the shielding of components such as the like, which is conducive to the heat dissipation during the operation of the copper bar assembly, the circuit board and the Hall chip, and avoids the influence of the energy efficiency, lifespan, etc. on the copper bar assembly, the circuit board, the Hall chip and other components in the electric drive controller caused by excessive temperature. Moreover, components such as housings are not provided in the electric drive copper bar structure, which has the advantage of small space occupation, and saves space to facilitate the arrangement of other components in the electric drive controller. Therefore, the electric drive copper bar structure of the embodiment of the present application can realize high precision and fast detection of current on the copper bar, and has good heat dissipation effect, small space occupation, and is convenient for arrangement, which is conducive to its comprehensive promotion and application.

[0008] Furthermore, the electrically driven copper busbar structure also includes a magnetic steel, which is connected to the connecting portion and is arranged close to the copper busbar and the Hall chip, and is used to amplify the magnetic field generated when the current flows through the copper busbar.

[0009] According to the above technical means, the magnet is used to amplify the magnetic field generated by the current flowing through the copper busbar, thereby increasing the magnetic field strength passing through the Hall chip. Even if a small current flows through the copper busbar, the Hall chip can generate enough Hall voltage for accurate measurement, so that the Hall chip can measure the current on the copper busbar with high accuracy.

[0010] Furthermore, the magnetic steels are arranged in pairs, the magnetic steels of a pair are arranged at intervals, and the Hall chip and the copper busbar are respectively arranged between the magnetic steels of a pair.

[0011] According to the above technical means, the current on the copper busbar can be measured with high precision and high response speed.

[0012] Furthermore, the circuit board is provided with an avoidance gap, and the magnetic steel is inserted into the avoidance gap.

[0013] According to the above technical means, interference between the magnetic steel and the circuit board is avoided to achieve the connection between the magnetic steel, the circuit board and the connecting part. Moreover, the setting of the avoidance gap can also reduce the overlapping part between the circuit board and the connecting part to avoid damage and adverse effects caused by heat accumulation on the circuit board and the connecting part.

[0014] Furthermore, the copper busbar assembly and the magnetic steel are an integral structural component.

[0015] According to the above technical means, the loosening and falling off of the magnetic steel can be prevented, and the assembly speed of the electric drive copper busbar structure can be improved.

[0016] Furthermore, the copper busbar includes an input end, an output end, and a middle section connecting the input end and the output end, the input end is located on one side of the connecting portion, the output end is located on the other side of the connecting portion, and the middle section is connected to the connecting portion; the Hall chip is arranged close to the input end.

[0017] According to the above technical means, the input end of the copper busbar inputs current, the output end outputs current, and the Hall chip is arranged close to the input end. The magnetic field generated when the current flows through the input end mainly acts on the Hall chip. This can avoid the current being affected during the copper busbar flow, resulting in deviation in the magnetic field intensity generated by the copper busbar, thereby reducing the accuracy of the Hall chip in detecting the current in the copper busbar.

[0018] Furthermore, the connecting portion is in a plate-like structure, and the connecting portion and the circuit board are stacked.

[0019] According to the above technical means, the connecting part occupies less space after being connected to the circuit board, and the connecting part can also effectively support the circuit board and provide protection for the circuit board.

[0020] Furthermore, a circuit is provided on the circuit board; the electric drive copper busbar structure also includes a connector, the connector is connected to the circuit board, and the connector is connected to the Hall chip through the circuit.

[0021] According to the above technical means, using a connector as a connecting piece for signal transmission between a circuit board and other components has the advantages of stable current signal transmission and simple and convenient connection.

[0022] An electric drive controller comprises a shell, wherein the electric drive copper busbar structure as described above is arranged inside the shell.

[0023] A car comprises a car body, wherein the car body is provided with the electric drive controller as described above.

[0024] Beneficial effects of the utility model:

[0025] (1) The electric drive copper busbar structure of the utility model uses a Hall chip to detect the current on the copper busbar, which has the advantages of high precision, fast response and strong anti-interference ability.

[0026] (2) The copper busbar assembly of the utility model includes a connecting portion and a copper busbar, wherein the connecting portion is connected to the copper busbar and the circuit board respectively; the Hall chip is connected to the circuit board and is arranged close to the copper busbar. The circuit board is directly connected to the connecting portion of the copper busbar assembly without being blocked by components such as a housing, which is conducive to heat dissipation during operation of the copper busbar assembly, the circuit board and the Hall chip, and avoids excessive temperature affecting the energy efficiency, lifespan, etc. of the copper busbar assembly, the circuit board, the Hall chip and other components in the electric drive controller.

[0027] (3) The electric drive copper busbar structure of the utility model does not include components such as a housing, which has the advantage of occupying a small space and saving space to facilitate the arrangement of other components in the electric drive controller.

[0028] (4) The input end of the copper busbar of the utility model inputs current, and the Hall chip is arranged close to the input end. When the current flows through the input end, the magnetic field generated mainly acts on the Hall chip. This can avoid the current being affected during the copper busbar flow, resulting in a deviation in the magnetic field intensity generated by the copper busbar, thereby reducing the accuracy of the Hall chip in detecting the current in the copper busbar.

[0029] (5) The connection part of the utility model is stacked with the circuit board. After the connection part is connected to the circuit board, it occupies a small space. In addition, the connection part can effectively support the circuit board and provide protection for the circuit board.

[0030] (6) The magnetic steel of the utility model is used to amplify the magnetic field generated by the current flowing through the copper busbar, thereby increasing the magnetic field strength passing through the Hall chip. When a relatively small current flows through the copper busbar, the Hall chip can generate sufficient Hall voltage for accurate measurement, so that the Hall chip can measure the current on the copper busbar with high accuracy.

[0031] (7) The magnetic steel and copper busbar assembly of the utility model is a plastic-coated structural component, which has the advantages of being neat and beautiful in appearance, being able to effectively connect the magnetic steel and the copper busbar, and protecting the magnetic steel and the copper busbar from damage. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 This is a schematic diagram of the structure of the electric drive copper busbar of the utility model;

[0033] Figure 2 It is a structural schematic diagram of the front view of the electric drive copper busbar structure of the utility model;

[0034] Figure 3 This is a schematic diagram of the structure of the copper busbar assembly of the utility model;

[0035] Figure 4 It is a partial structural schematic diagram of the electric drive controller of the utility model.

[0036] Among them, 1 is a circuit board; 11 is a avoidance gap; 2 is a Hall chip; 3 is a copper busbar assembly; 31 is a connecting part; 32 is a copper busbar; 33 is an input end; 34 is an output end; 4 is a magnet; 5 is a connector; 6 is a housing; 7 is a power module; 81 is a first bolt; 82 is a second bolt. DETAILED DESCRIPTION

[0037] The following will describe the implementation of the present invention with reference to the accompanying drawings and preferred embodiments. Those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. The present invention can also be implemented or applied through other different specific implementations, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention. It should be understood that the preferred embodiments are only for illustrating the present invention, not for limiting the scope of protection of the present invention.

[0038] It should be noted that the illustrations provided in the following embodiments are only schematic illustrations of the basic concept of the present invention, and thus the drawings only show components related to the present invention rather than being drawn according to the number, shape and size of components in actual implementation. In actual implementation, the type, quantity and proportion of each component may be changed at will, and the component layout may also be more complicated.

[0039] This embodiment proposes an electric drive copper busbar structure suitable for use in an electric drive controller. Figures 1 to 4 As shown, the electric drive copper busbar structure includes a copper busbar assembly 3, a circuit board 1 and a Hall chip 2; the copper busbar assembly 3 includes a connecting portion 31 and a copper busbar 32, and the connecting portion 31 is connected to the copper busbar 32 and the circuit board 1 respectively; the Hall chip 2 is connected to the circuit board 1 and is arranged close to the copper busbar 32; the copper busbar 32 generates a magnetic field when current flows through it, and the Hall chip 2 detects the current on the copper busbar 32 according to the magnetic field acting thereon.

[0040] Among them, the copper busbar 32 in the copper busbar assembly 3 is one of the important components in the electric drive controller. One end of the copper busbar 32 is used to connect to the motor, and the other end of the copper busbar 32 is used to connect to the power module 7 in the electric drive controller. The functions of the copper busbar 32 include current transmission, heat dissipation and structural support. For current transmission: the copper busbar 32 is a good conductor, which is used to transmit large currents inside the electric drive controller to ensure that the current flows efficiently. For heat dissipation: copper has good thermal conductivity. When the electric drive controller is running, heat will be generated. The copper busbar 32 can help conduct this heat to the radiator or other parts, which helps to dissipate heat, so that the temperature of the electric drive controller is within a safe range. For structural support: the copper busbar 32 can also be used as a structural element to provide mechanical support for the electric drive controller, and assist in the installation and connection stability of the electric drive controller.

[0041] The copper busbar 32 usually carries a high current density when in use. Since the copper busbar 32 has the above-mentioned functions and in order to ensure the safe, stable and efficient operation of the electric drive controller, it is necessary to detect the current of the copper busbar 32 to achieve the purposes of safety protection, efficiency optimization, fault diagnosis, etc. Among them, for safety protection: by real-time monitoring of the current of the copper busbar 32, it can be ensured that the current flowing through the copper busbar 32 does not exceed the maximum current limit designed for the copper busbar 32, thereby avoiding the occurrence of overload conditions to prevent damage to electrical components or fire. For efficiency optimization: the magnitude of the current on the copper busbar 32 is directly related to the power output and energy efficiency of the motor. By accurately controlling the current on the copper busbar 32, it can be ensured that the motor operates at the most efficient operating point, thereby improving the energy utilization rate and cruising range of the vehicle. For fault diagnosis: abnormal fluctuations in the current on the copper busbar 32 may be an early sign of internal faults in the motor or electric drive controller. By monitoring the current on the copper busbar 32, potential problems such as short circuits, poor contact or motor demagnetization can be discovered in a timely manner, and repairs or replacements can be performed before the problem worsens to ensure the safety of the motor or electric drive controller.

[0042] The printed circuit board 1 (PCB) is a basic component used to connect electronic components in electronic devices. The circuit board 1 is composed of an insulating substrate and a conductive pattern attached thereto, which is made by etching or printing. The circuit board 1 in the embodiment of the present application provides electrical connection for the Hall chip 2 and supports the position of the Hall chip 2 in the circuit board 1.

[0043] The Hall chip 2 is an electronic component based on the Hall effect principle, which includes a Hall element and necessary electronic circuits. The embodiment of the present application does not specifically limit the structure of the Hall chip 2. Among them, the Hall effect refers to the phenomenon that when a conductor (in the embodiment of the present application, the conductor is a copper bar 32) is placed in a magnetic field and a current passes through, the charge carriers in the conductor are deflected to one side by the Lorentz force, and then a voltage (Hall voltage) is generated. The main function of the Hall chip 2 is to detect the current on the conductor according to the magnetic field acting on it. In the embodiment of the present application, when the Hall chip 2 is working and a current flows through the copper bar 32, the copper bar 32 will generate a magnetic field, and this magnetic field will act on the Hall chip 2. The Hall chip 2 generates a Hall voltage according to the magnetic field acting on it, and then the electronic circuit inside the Hall chip 2 converts this voltage into a standard output signal, such as a voltage or current signal, etc., and the current on the copper bar 32 can be obtained according to this output signal.

[0044] In the embodiment of the present application, the copper bar assembly 3 includes a connecting portion 31 and a copper bar 32, and the connecting portion 31 is connected to the copper bar 32 and the circuit board 1 respectively; the Hall chip 2 is connected to the circuit board 1 and is arranged near the copper bar 32; the copper bar 32 generates a magnetic field during the current flowing through the copper bar 32, and the Hall chip 2 detects the current on the copper bar 32 according to the magnetic field acting thereon. Using the Hall chip 2 to detect the current on the copper bar 32 has the advantages of high precision, fast response and strong anti-interference ability. The circuit board 1 is directly connected to the connecting portion 31 of the copper bar assembly 3, without the shielding of components such as the housing, which is conducive to the heat dissipation of the copper bar assembly 3, the circuit board 1 and the Hall chip 2 during operation, and avoids the influence of excessive temperature on the energy efficiency, life, etc. of the copper bar assembly 3, the circuit board 1, the Hall chip 2 and other components in the electric drive controller. Moreover, the electric drive copper bar structure does not have components such as the housing, which has the advantage of occupying a small space, saving space to facilitate the arrangement of other components in the electric drive controller. Therefore, the electric-driven copper busbar structure of the embodiment of the present application can realize high-precision and rapid detection of the current on the copper busbar 32, and has the advantages of good heat dissipation effect, small space occupation, and convenient layout, which is conducive to its comprehensive promotion and application.

[0045] In this embodiment, refer to Figure 2 and Figure 3 As shown, the copper bus 32 includes an input end 33, an output end 34, and a middle section connecting the input end 33 and the output end 34. The input end 33 is located on one side of the connecting portion 31, the output end 34 is located on the other side of the connecting portion 31, and the middle section is connected to the connecting portion 31; the Hall chip 2 is arranged near the input end 33.

[0046] When the electric drive copper busbar structure is in use, the input end 33 of the copper busbar 32 is connected to the power module 7, and the output end 34 of the copper busbar 32 is connected to the motor. Current is input to the input end 33 of the copper busbar 32, and the current flows through the input end 33, the middle section and the output end 34 in sequence, and then flows out from the output end 34.

[0047] When current flows through the copper bar 32, a magnetic field is generated, and the strength of the magnetic field is proportional to the magnitude of the current. Since the input terminal 33 of the copper bar 32 inputs current, and the Hall chip 2 is arranged close to the input terminal 33, the magnetic field generated when the current flows through the input terminal 33 mainly acts on the Hall chip 2. This can prevent the current from being affected during the copper bar 32 flow, resulting in a deviation in the magnetic field strength generated by the copper bar 32, thereby reducing the accuracy of the Hall chip 2 detecting the current in the copper bar 32.

[0048] In this embodiment, the connecting portion 31 is a plate-like structure, and the connecting portion 31 is stacked with the circuit board 1. When the connecting portion 31 is stacked with the circuit board 1, the connecting portion 31 occupies less space after being connected to the circuit board 1, and the connecting portion 31 can also effectively support the circuit board 1 and provide protection for the circuit board 1.

[0049] In this embodiment, the input end 33 of the copper busbar 32 and the connecting portion 31 are perpendicular to each other, and the circuit board 1 is arranged in the space surrounded by the input end 33 of the copper busbar 32 and the connecting portion 31. The input end 33 and the connecting portion 31 can jointly protect the circuit board 1 to prevent the circuit board 1 from being damaged by bumps and the like. Moreover, the circuit board 1 is arranged in the space surrounded by the input end 33 of the copper busbar 32 and the connecting portion 31, and does not need to occupy other space, so that the electric drive copper busbar structure occupies less space.

[0050] Further, see Figure 3 As shown, the input end 33 of the copper busbar 32 extends toward one side of the connecting portion 31 , and the output end 34 of the copper busbar 32 extends toward the other side of the connecting portion 31 . The extending directions of the input end 33 and the output end 34 are opposite.

[0051] In this embodiment, the electrically driven copper busbar structure further includes a magnetic steel 4, which is connected to the connecting portion 31 and is disposed close to the copper busbar 32 and the Hall chip 2. The magnetic steel 4 is used to amplify the magnetic field generated when the current flows through the copper busbar 32.

[0052] The magnetic steel 4 is a strong magnetic material, which can be used to enhance the magnetic field passing through the Hall chip 2. In the embodiment of the present application, the specific type of the magnetic steel 4 is not limited. For example, the magnetic steel 4 is a silicon steel sheet, a soft magnetic alloy, a hard magnetic alloy, etc., whichever meets the use requirements.

[0053] In the embodiment of the present application, the magnetic steel 4 is used to amplify the magnetic field generated when the current flows through the copper busbar 32, thereby increasing the magnetic field strength passing through the Hall chip 2. In this way, even if a relatively small current flows through the copper busbar 32, sufficient Hall voltage can be generated in the Hall chip 2 for accurate measurement, so that the Hall chip 2 can measure the current on the copper busbar 32 with high accuracy.

[0054] In this embodiment, the magnetic steels 4 are arranged in pairs, and a pair of magnetic steels 4 are arranged at intervals, and a Hall chip 2 and a copper bus 32 are respectively arranged between the pair of magnetic steels 4.

[0055] When current passes through the copper busbar 32, a magnetic field is generated between the magnetic steels 4. After the Hall chip 2 senses the magnetic field acting thereon, it outputs a voltage signal proportional to the current. According to the voltage signal, the Hall chip 2 can detect the current on the copper busbar 32. In the embodiment of the present application, by respectively providing the Hall chip 2 and the copper busbar 32 between a pair of magnetic steels 4, the current on the copper busbar 32 can be measured with high precision and high response speed.

[0056] In this embodiment, the copper busbar 32 is a three-phase copper busbar. There are three copper busbars 32, each copper busbar 32 represents a phase. In a three-phase AC circuit, the voltage and current between the three phases are 120 degrees different from each other. Such a configuration can provide a more stable power supply and higher energy efficiency. Figure 2and Figure 3 As shown, there is a certain distance between two adjacent copper bars 32 to facilitate air circulation and enhance the natural convection cooling effect. Because when the electric drive controller is running, the current flowing on the copper bar will generate heat. If there is not enough distance between two adjacent copper bars 32, the heat may accumulate between the copper bars, resulting in excessive temperature, affecting the performance and reliability of the electric drive controller. A certain distance between two adjacent copper bars 32 can also ensure insulation and prevent electrical failures; help maintain the mechanical stability of the copper bars 32 to prevent them from contacting or deforming each other under vibration or impact; and help reduce the generation and propagation of electromagnetic interference, and improve the accuracy of the Hall chip 2 in measuring the current on the copper bar 32.

[0057] Further references Figures 1 to 3 As shown, there are three copper bars 32, three pairs of magnetic steels 4, and three Hall chips 2. A Hall chip 2 and a copper bar 32 are arranged between each pair of magnetic steels 4. Figure 2 In the left and right direction, the Hall chip 2 and the copper bus 32 are located in the middle of a pair of magnetic steels 4.

[0058] Further references Figure 2 As shown, three copper bars 32 are arranged in a row from left to right, six magnetic steels 4 are arranged in a row, and three Hall chips 2 are arranged in a row. The arrangement directions of the three copper bars 32, the six magnetic steels 4, and the three Hall chips 2 are parallel.

[0059] In this embodiment, the magnetic steel 4 and the circuit board 1 are located on the same surface of the connecting portion 31. In order to avoid the magnetic steel 4 and avoid interference between the magnetic steel 4 and the circuit board 1, so as to achieve the connection between the magnetic steel 4 and the circuit board 1 and the connecting portion 31, an avoidance notch 11 is provided on the circuit board 1, and the magnetic steel 4 is inserted into the avoidance notch 11.

[0060] In the above structure of the embodiment of the present application, when the circuit board 1 and the connecting part 31 are connected, the magnetic steel 4 can pass through the avoidance gap 11 to avoid interference between the circuit board 1 and the magnetic steel 4, so that the magnetic steel 4 and the circuit board 1 can be connected to the same surface of the connecting part 31.

[0061] Further references Figure 2 As shown, the circuit board 1 is provided with a relief notch 11 at one end close to the input end 33 of the copper busbar 32, and the relief notch 11 is a rectangular notch, which has the advantages of regular shape and simple and convenient processing. Moreover, the provision of the relief notch 11 can also reduce the overlap between the circuit board 1 and the connecting portion 31, so as to avoid damage and adverse effects caused by heat accumulation on the circuit board 1 and the connecting portion 31.

[0062] In the embodiment of the present application, the number of the avoidance gaps 11 is set according to the use requirements, for example, referring to Figure 2 As shown, there are three copper bars 32, three pairs of magnetic steels 4, and three Hall chips 2. A Hall chip 2 and a copper bar 32 are provided between each pair of magnetic steels 4. An avoidance gap 11 is provided between two adjacent Hall chips 2, and the avoidance gap 11 is used to place two magnetic steels 4 close to each other in two adjacent pairs of magnetic steels 4. The avoidance gap 11 is provided at the leftmost and rightmost ends of the circuit board 1 according to the use requirements. For example, when the leftmost end of the circuit board 1 will interfere with the magnetic steel 4, the avoidance gap 11 is provided at the leftmost end of the circuit board 1. When the rightmost end of the circuit board 1 will not interfere with the magnetic steel 4, the avoidance gap 11 does not need to be provided at the rightmost end of the circuit board 1.

[0063] In this embodiment, in order to facilitate the installation of the circuit board 1, there is a gap between the edge of the circuit board 1 avoiding the notch 11 and the magnetic steel 4. The gap can prevent the circuit board 1 and the magnetic steel 4 from being damaged by collision when the circuit board 1 is connected to the connecting portion 31.

[0064] In this embodiment, the arrangement of the avoidance notch 11 on the circuit board 1 makes the circuit board 1 present a comb-tooth structure. The Hall chip 2 is located on the comb teeth of the comb-tooth structure. Figure 2 In the embodiment, the width of the comb teeth in the left-right direction is adapted to the width of the copper bus 32 in the left-right direction, so as to minimize the overlapping part between the circuit board 1 and the connecting part 31. A mounting hole is provided on the comb handle of the comb-tooth structure, and a second bolt 82 or other fasteners pass through the mounting hole and are connected to the connecting part 31, so as to detachably connect the circuit board 1 and the connecting part 31. Connecting the circuit board 1 and the connecting part 31 by means of fasteners such as the second bolt 82 has the advantages of simple and convenient connection, as well as convenient maintenance and replacement. The embodiment of the present application does not specifically limit the number of fasteners such as the second bolt 82, so that the circuit board 1 and the connecting part 31 are securely connected. For example, referring to Figure 2 As shown, three second bolts 82 are provided, and the three second bolts 82 are arranged at intervals in the left-right direction.

[0065] In this embodiment, in order to prevent the magnetic steel 4 from loosening and falling off, thereby affecting the accuracy of the Hall chip 2 measuring the current on the copper bus 32, the copper bus assembly 3 and the magnetic steel 4 are an integrated structure.

[0066] In this embodiment, the magnetic steel 4 and the copper bar assembly 3 are plastic-coated structural parts. Among them, plastic coating refers to a plastic sealing process in which a plastic sheet is fixed in a heat-sealing mold, and then the mold is heated to melt the sheet and then bonded to the wrapped object (in the embodiment of the present application, the wrapped object includes the copper bar 32 and the magnetic steel 4). The characteristics of plastic coating are neat and beautiful appearance, and can protect the shape and texture of the wrapped object. Therefore, when the magnetic steel 4 and the copper bar assembly 3 are plastic-coated structural parts, they have the advantages of neat and beautiful appearance, can effectively realize the connection between the magnetic steel 4 and the copper bar 32, and realize the protection of the magnetic steel 4 and the copper bar 32, and avoid damage to the magnetic steel 4 and the copper bar 32.

[0067] In the embodiment of the present application, the copper busbar assembly 3 and the magnetic steel 4 may also be connected to form an integrated structural member in other ways, and the embodiment of the present application does not specifically limit this.

[0068] In this embodiment, a circuit is provided on the circuit board 1; the electric drive copper busbar structure further includes a connector 5, the connector 5 is connected to the circuit board 1, and the connector 5 is connected to the Hall chip 2 through the circuit.

[0069] The circuit on the circuit board 1 refers to the various electronic components and their connection methods designed and arranged on the circuit board 1, which together constitute a complete electronic system. In the embodiment of the present application, the circuit on the circuit board 1 includes a conductive pattern attached to an insulating substrate, a Hall chip 2, and other electronic components set according to usage requirements (it can be understood that the types and settings of the electronic components on the circuit board 1 in the embodiment of the present application are set according to the usage requirements of the electric drive copper busbar structure, and the embodiment of the present application does not specifically limit this.)

[0070] Connector 5 refers to an electrical connector. Connector 5 is a device for electrical connection, which allows quick connection and disconnection between two or more cables, wires or circuit boards 1. Connector 5 has a male end and a female end, and the male end and the female end can transmit information or current after contact. In the embodiment of the present application, one of the male end and the female end of connector 5 is connected to circuit board 1, and the other of the male end and the female end of connector 5 is connected to other components (such as a control unit, etc., a component that receives the current signal of the copper bus 32 transmitted by the Hall chip 2). When the electric drive copper bus structure is installed in the electric drive controller, the male end and the female end of connector 5 are in contact to realize the transmission of the current signal.

[0071] In this embodiment, the connector 5 is used as a connector for signal transmission between the circuit board 1 and other components, which has the advantages of stable current signal transmission and simple and convenient connection.

[0072] Furthermore, the connector 5 is located at one end of the circuit board 1, and the connector has enough space to connect with other components to avoid interference between the connector 5 and other components. Figure 2 As shown, the connector 5 is located at the left end of the circuit board 1 .

[0073] In this embodiment, the electric drive copper bar structure includes a copper bar assembly 3, a magnetic steel 4, a Hall chip 2 and a circuit board 1. The copper bar assembly 3 and the magnetic steel 4 are plastic-coated structural parts, that is, the copper bar assembly 3 and the magnetic steel 4 are an integral structural part; the Hall chip 2 is connected to the circuit board 1 as a whole. When the electric drive copper bar structure is assembled, it is only necessary to connect the circuit board 1 and the copper bar assembly 3 through fasteners such as the second bolt 82 to realize the assembly of the electric drive copper bar structure, which has the advantage of a simple and convenient connection structure. Moreover, the circuit board 1 and the magnetic steel 4 are located between the input end 33 and the connecting portion 31 of the copper bar 32, and the circuit board 1 and the connecting portion 31 are stacked, and the circuit board 1 does not occupy other space, so that the space occupied by the electric drive copper bar structure is small; the input end 33 and the connecting portion 31 of the copper bar 32 can also play a role in protecting the circuit board 1 and the magnetic steel 4, avoiding damage such as bumps on the circuit board 1 and the magnetic steel 4.

[0074] Reference Figure 2 and Figure 3 As shown, three Hall chips 2 are arranged on the circuit board 1, and the copper bar assembly 3 includes three copper bars 32. The Hall chips 2 and the copper bars 32 are arranged one by one, and two magnets 4 are arranged on both sides of each Hall chip 2. When current passes through the copper bar 32, the copper bar 32 will generate a magnetic field, and the magnet 4 will strengthen the magnetic field generated by the copper bar 32. As the current changes, the magnetic field strength on the copper bar 32 will change. At this time, the Hall chip 2 receives the change in the magnetic field strength and transmits the corresponding signal to other components through the connector 5, such as the controller for corresponding strategy control processing, thereby effectively controlling the entire current signal.

[0075] The magnetic steel 4 and the circuit board 1 are connected to the same surface of the connecting portion 31. In order to avoid interference between the circuit board 1 and the magnetic steel 4 and realize the connection between the magnetic steel 4, the circuit board 1 and the connecting portion 31, the circuit board 1 is provided with an avoidance notch 11, and the magnetic steel 4 is inserted into the avoidance notch 11. Moreover, the arrangement of the avoidance notch 11 on the circuit board 1 can also reduce the overlapping portion between the circuit board 1 and the connecting portion 31, so as to avoid damage and adverse effects caused by heat accumulation on the circuit board 1 and the connecting portion 31.

[0076] The connection part 31 of the electric drive copper bar structure is respectively connected to the copper bar 32 and the circuit board 1; the Hall chip 2 is connected to the circuit board 1 and is arranged near the copper bar 32; the copper bar 32 generates a magnetic field during the current flowing through the copper bar 32, and the Hall chip 2 detects the current on the copper bar 32 according to the magnetic field acting thereon. Using the Hall chip 2 to detect the current on the copper bar 32 has the advantages of high precision, fast response and strong anti-interference ability. The circuit board 1 is directly connected to the connection part 31 of the copper bar assembly 3, without any shielding components, which is conducive to the heat dissipation of the copper bar assembly 3, the circuit board 1 and the Hall chip 2 during operation, and avoids the influence of excessive temperature on the energy efficiency, life, etc. of the copper bar assembly 3, the circuit board 1, the Hall chip 2 and other components in the electric drive controller. Moreover, the electric drive copper bar structure does not have components such as a housing, which has the advantage of occupying a small space, saving space to facilitate the arrangement of other components in the electric drive controller. Therefore, the electric drive copper busbar structure of the embodiment of the present application can achieve high-precision and rapid detection of the current on the copper busbar 32, and has the advantages of good heat dissipation effect, small space occupation, conducive to heat dissipation of parts, convenient vehicle layout, and strong practicality.

[0077] This embodiment provides an electric drive controller, which includes a housing 6 , in which the electric drive copper busbar structure as described above is arranged.

[0078] Among them, the electric drive controller is a key component in electric vehicles or electric motorcycles. Its main function is to control the operation of the electric motor, including starting, accelerating, decelerating and stopping. The electric drive controller receives instructions from the driver (such as accelerator pedal depth, brake pedal position, etc.), and adjusts the power output and speed of the electric motor according to these instructions to achieve the power and controllability of the vehicle.

[0079] The electric drive controller includes a housing 6, which encloses an installation cavity, and the electric drive copper busbar structure is arranged in the installation cavity. The housing 6 can protect the electric drive copper busbar structure. Figure 1 As shown, the electric drive copper busbar structure is connected to the housing 6 via a first bolt 81, which has the advantage of a simple and convenient connection structure.

[0080] In the embodiment of the present application, the housing 6 of the electric drive controller is provided with an electric drive copper bar structure as described above. The electric drive copper bar structure includes a copper bar assembly 3, a magnetic steel 4, a Hall chip 2 and a circuit board 1. The copper bar assembly 3 and the magnetic steel 4 are an integrated structural member; the Hall chip 2 is connected to the circuit board 1 as a whole, and the connecting portion 31 of the copper bar assembly 3 is stacked with the circuit board 1. After the copper bar assembly 3 is connected to the circuit board 1, it takes up less space, and the connecting portion 31 can also effectively support the circuit board 1 and provide protection for the circuit board 1. The circuit board 1 and the magnetic steel 4 are located between the input end 33 and the connecting portion 31 of the copper bar 32 in the copper bar assembly 3. The input end 33 and the connecting portion 31 of the copper bar 32 can also play a role in protecting the circuit board 1 and the magnetic steel 4, and avoid damage such as bumps on the circuit board 1 and the magnetic steel 4. Using the Hall chip 2 to detect the current on the copper bar 32 has the advantages of high precision, fast response and strong anti-interference ability. The circuit board 1 is directly connected to the connecting portion 31 of the copper busbar assembly 3, without the shielding of components such as the housing, which is conducive to the heat dissipation of the copper busbar assembly 3, the circuit board 1 and the Hall chip 2 during operation, and avoids the influence of excessive temperature on the energy efficiency, lifespan, etc. of the copper busbar assembly 3, the circuit board 1, the Hall chip 2 and other components in the electric drive controller. Moreover, components such as the housing are not provided in the electric drive copper busbar structure, which has the advantage of occupying a small space, saving space to facilitate the arrangement of other components in the electric drive controller. Therefore, the electric drive controller of the embodiment of the present application has the advantages of high precision and rapid detection of the current on the copper busbar 32, and has the advantages of occupying a small space and good heat dissipation effect.

[0081] Reference Figure 4 As shown, the electric drive controller further includes a power module 7, and the input end 33 of the copper busbar 32 is connected to the power module 7. The main function of the power module 7 is to convert the direct current DC provided by the battery into the alternating current AC required by the motor and control the power output of the motor.

[0082] Further references Figure 4 As shown, the circuit board 1 is connected to the surface of the connection part 31 facing the power module 7, and the circuit board 1 is located between the connection part 31, the input end 33 of the copper bus 32 and the power module 7, which can prevent the circuit board 1 from being damaged by bumps and the like.

[0083] It is understandable that the electric drive controller also includes components such as a control unit. The embodiment of the present application does not specifically limit the components in the electric drive controller as long as the usage requirements are met.

[0084] This embodiment also provides a car, including a car body, and the car body is provided with the electric drive controller as described above.

[0085] Since the electric drive controller can realize high-precision and rapid detection of the current on the copper busbar 32, as well as effective output, and also has the advantage of good heat dissipation, the electric drive controller can quickly respond to the driver's operating instructions while ensuring efficient, stable and safe operation, thereby improving the user satisfaction of the car.

[0086] It should be noted that the electric drive copper bus structure, the electric drive controller and the automobile can refer to each other and have the same or similar beneficial effects as any of the aforementioned electric drive copper bus structures. In order to avoid repetition, they will not be described one by one here.

[0087] The above embodiments are only preferred embodiments for fully illustrating the present invention, and the protection scope of the present invention is not limited thereto. Any equivalent substitution or modification made by a person skilled in the art based on the present invention is within the protection scope of the present invention.

Claims

1. An electric drive copper busbar structure, characterized in that: It comprises a copper busbar assembly (3), a circuit board (1) and a Hall chip (2); the copper busbar assembly (3) comprises a connecting portion (31) and a copper busbar (32); the connecting portion (31) is connected to the copper busbar (32) and the circuit board (1) respectively; The Hall chip (2) is connected to the circuit board (1) and is arranged close to the copper bus (32); The copper bus (32) generates a magnetic field when current flows through it, and the Hall chip (2) detects the current on the copper bus (32) based on the magnetic field acting on it.

2. The electric drive copper busbar structure according to claim 1, characterized in that: The electrically driven copper busbar structure further comprises a magnetic steel (4), the magnetic steel (4) being connected to the connecting portion (31) and being arranged close to the copper busbar (32) and the Hall chip (2), the magnetic steel (4) being used to amplify the magnetic field generated when the current flows through the copper busbar (32).

3. The electric drive copper busbar structure according to claim 2, characterized in that: The magnetic steels (4) are arranged in pairs, a pair of the magnetic steels (4) are arranged at intervals, and the Hall chip (2) and the copper busbar (32) are respectively arranged between the pair of the magnetic steels (4).

4. The electric drive copper busbar structure according to claim 3, characterized in that: The circuit board (1) is provided with an escape notch (11), and the magnetic steel (4) is inserted into the escape notch (11).

5. The electric drive copper busbar structure according to claim 2, characterized in that: The copper busbar assembly (3) and the magnetic steel (4) are an integrated structural component.

6. The electric drive copper busbar structure according to claim 1, characterized in that: The copper busbar (32) comprises an input end (33), an output end (34), and a middle section connecting the input end (33) and the output end (34); the input end (33) is located on one side of the connecting portion (31), the output end (34) is located on the other side of the connecting portion (31), and the middle section is connected to the connecting portion (31); and the Hall chip (2) is arranged close to the input end (33).

7. The electric drive copper busbar structure according to claim 1, characterized in that: The connecting portion (31) is in a plate-like structure, and the connecting portion (31) and the circuit board (1) are stacked.

8. The electric drive copper busbar structure according to claim 1, characterized in that: The circuit board (1) is provided with a circuit; The electrically driven copper busbar structure further comprises a connector (5), wherein the connector (5) is connected to the circuit board (1), and the connector (5) is connected to the Hall chip (2) via the circuit.

9. An electric drive controller, comprising a housing (6), characterized in that: The housing (6) is provided with an electric drive copper busbar structure as claimed in any one of claims 1 to 8.

10. An automobile, comprising a vehicle body, characterized in that: The vehicle body is provided with the electric drive controller as claimed in claim 9.

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