Motor controller, voltage converter and high-voltage power distribution and vehicle-mounted charging integrated device

Abstract

The utility model discloses a motor controller, a voltage converter, a high-voltage power distribution and vehicle-mounted charging integrated device, which comprises a shell of which the upper part and the lower part are not sealed, and the top and the bottom of the shell are detachably connected with an upper cover plate and a lower cover plate respectively to form a closed device body. A fast charging positive and negative terminal, a battery positive and negative terminal, a three-phase output terminal, a DC terminal, a first PTC and air conditioner terminal, a second PTC terminal, an upper mounting terminal, an OBC terminal, a low-voltage signal terminal, a ventilation valve, a grounding terminal and at least two water nozzles are connected to the outside of the device body. The interior of the device body is divided into a closed upper cavity and a closed lower cavity by at least two transverse heat dissipation plates, a heat dissipation water channel is arranged between the heat dissipation plates, the upper cavity is provided with a motor controller MCU and a high-voltage power distribution module which are electrically connected with each other, and the lower cavity is provided with a two-in-one module of a voltage converter and a vehicle-mounted charger OBC. The utility model has the advantages of small volume, high power density, high cooling efficiency and stable product performance.

Description

Technical Field

[0001] The utility model belongs to the fields of pure electric and hybrid vehicle charging technologies and voltage conversion, and particularly relates to an integrated device of a motor controller, a voltage converter, high-voltage power distribution and on-vehicle charging. Background Art

[0002] Under the background of energy crisis, energy conservation and environmental protection, new energy vehicles have become the development trend of the automotive industry. The industry scale is constantly expanding, the market demand is growing rapidly, driving the rapid development of motor drive technology. With the continuous improvement of the market's requirements for electric vehicle motor control, the electric vehicle industry's requirements for the power, volume, weight, drive efficiency, etc. of the controller are constantly increasing. High power, miniaturization, lightweight, and high conversion efficiency have become the development trend of motor controller products. Content of the Utility Model

[0003] The purpose of the utility model is to provide an integrated device of a motor controller, a voltage converter, high-voltage power distribution and on-vehicle charging, which has a small product volume, a high power density, a high cooling efficiency and stable product performance.

[0004] To solve the above technical problems, the technical solution of the utility model is as follows: it includes a shell with open top and bottom. The top and bottom of the shell are respectively detachably connected with an upper cover plate and a lower cover plate to form a closed device body. The outer part of the device body is respectively connected with fast charge positive and negative terminals, battery positive and negative terminals, three-phase output terminals, DC terminals, a first PTC, and air-conditioning terminals, a second PTC terminal, an upper-mounted terminal, an OBC terminal, a low-voltage signal terminal, a breather valve, a ground terminal and at least two water nozzles; the interior of the device body is separated by at least two horizontal heat dissipation plates to form a sealed upper cavity and a lower cavity. A heat dissipation water channel is arranged between the heat dissipation plates. The upper cavity is provided with a motor controller MCU and a high-voltage power distribution module that are electrically connected to each other. The lower cavity is provided with a voltage converter and an on-vehicle charger OBC two-in-one module; among them, the first PTC, and the air-conditioning terminals, the second PTC terminal, the upper-mounted terminal, the OBC terminal, the low-voltage signal terminal are respectively connected to the high-voltage power distribution module, serving as different gear output ports for power distribution and used for supplying power to external devices; the three-phase output terminals are connected to an external motor; the voltage converter and the on-vehicle charger OBC two-in-one module are respectively connected to the OBC terminal and the DC terminal; the fast charge positive and negative terminals and the battery positive and negative terminals are respectively used as fast charge range extension and battery input ports; the breather valve is communicated with the interior of the device body; the water nozzles are connected to the heat dissipation water channel, and two water nozzles form a group of water inlet and outlet, and each group of water inlet and outlet includes a water outlet and a water inlet; the ground terminal is connected to an external ground terminal to play a protective role; the motor controller MCU is electrically connected to each terminal outside the device body.

[0005] The motor controller MCU includes a power module and its drive circuit board, a bus capacitor, a control board, and an external interface circuit board; among them, the power module and its drive circuit board are installed on a heat dissipation plate, and the 6 DC terminals of the bus capacitor are lapped on the 6 DC terminals of the power module; the three-phase terminals of the power module are connected to the three-phase output terminals, the control board is installed on the control board support plate of the housing, the signal ports of the control board are connected to the drive board on the power module through signal cables, the control board performs electrical control on the power module, and the external interface circuit board is used for electrical connection with the external terminals of the device body.

[0006] A large current fuse is provided in the formation circuit of the fast charge positive and negative terminals.

[0007] The high-voltage power distribution module includes a power distribution terminal block, an accessory circuit board, a small current fuse, a high-voltage detector, a pre-charge contactor, and a small current contactor; among them, the small current contactor and the pre-charge contactor are installed on the power distribution terminal block, the bottom of the accessory circuit board is connected to the power distribution terminal block, the first PTC, the air conditioner terminal, the second PTC terminal, the upper mounting terminal, the OBC terminal, and the low-voltage signal terminal are respectively connected to the power distribution terminal block; the top of the accessory circuit board is connected to the small current fuse and the high-voltage detector, and the high-voltage detector is connected to the accessory circuit board through a control line.

[0008] It also includes a first large current contactor, a second large current contactor, and a third large current contactor. The second large current contactor is connected to the positive pole of the bus capacitor through a copper bar, the negative pole of the battery positive and negative terminals is connected to the first large current contactor through a copper bar, the first large current contactor is connected to the negative pole of the bus capacitor through a copper bar, the fast charge positive and negative terminals are connected to the small current fuse through a copper bar, the small current fuse is connected to the third large current contactor, the third large current contactor is connected to the second large current contactor, and the second large current contactor is connected to the positive pole of the battery positive and negative terminals through a copper bar.

[0009] Three control lines are connected from the output terminal of the high-voltage detector and are respectively connected to the input terminal and the output terminal of the first large current contactor and the input terminal of the third large current contactor. Through this connection method, high-voltage detection is realized.

[0010] A small cover plate detachably connected to the upper cover plate is provided on the upper cover plate.

[0011] The control board is connected to the housing through a control board support.

[0012] Compared with the prior art, the beneficial effects of the present utility model are:

[0013] 1. Both the upper and lower cover plates of the casing are detachable, and there is a small cover plate on the upper cover plate, which is convenient for the assembly of high-voltage wiring harnesses and the replacement of fuses;

[0014] 2. On the upper cavity of the housing, a circuit board for installing the motor controller MCU and the high-voltage power distribution module is provided; on the lower cavity of the housing, a voltage converter DCDC and an on-vehicle charger OBC two-in-one module are installed, and the output port of the high-voltage power distribution system is integrated to make full use of the space.

[0015] 3. The high-voltage power distribution system is highly integrated and assembled modularly. While meeting the functions, a hierarchical design is adopted to save the assembly space.

[0016] 4. The cooling water channel has multiple functions. The upper cavity is used for dissipating heat of the IGBT power module and the bus capacitor, and the lower cavity is used for dissipating heat of the voltage converter DCDC and the on-vehicle charger OBC two-in-one module.

[0017] 5. The high-voltage detection function is added to achieve timeliness in the action of controlling the main positive and fast-charging contactors to close (detecting the high-voltage signal and then closing the contactor), and at the same time, it can ensure that the fuse in the fast-charging circuit is in a normal state.

[0018] 6. Inside the high-voltage distributor, the connection method through the terminal block enhances the stability of overcurrent. Description of the Drawings

[0019] Figure 1 It is a schematic structural diagram of an embodiment of the present invention;

[0020] Figure 2 It is a side view of an embodiment of the present invention;

[0021] Figure 3 It is a side view after flipping an embodiment of the present invention;

[0022] Figure 4 It is a schematic structural diagram of the upper cavity in an embodiment of the present invention;

[0023] Figure 5 It is a schematic structural diagram of the lower cavity in an embodiment of the present invention;

[0024] Figure 6 It is a schematic structural diagram of the high-voltage power distribution module in an embodiment of the present invention;

[0025] Figure 7 It is an installation schematic diagram of the water channel cover plate in an embodiment of the present invention;

[0026] Figure 8 It is a sectional view of the side view in an embodiment of the present invention;

[0027] Figure 9 It is an electrical schematic diagram of an embodiment of the present invention;

[0028] In the figure, 1 - housing, 2 - terminal cover plate, 3 - fast charging positive and negative terminals, 4 - battery positive and negative terminals, 5 - three-phase output terminals, 6 - DC terminals, 7 - water nozzle, 8 - OBC terminals, 9 - first PTC + air conditioner terminals, 10 - second PTC terminals, 11 - small cover plate, 12 - upper cover plate, 13 - grounding terminals, 14 - upper mounting terminals, 15 - breather valve, 16 - lower cover plate, 17 - first high-current contactor, 18 - second high-current contactor, 19 - third high-current contactor, 20 - bus capacitor, 21 - power module IGBT and its drive circuit board, 22 - MCU control circuit board, 23 - external interface circuit board, 24 - high-voltage power distribution module, 25 - voltage converter DCDC and OBC integrated module, 26 - high-voltage detector, 27 - small-current fuse, 28 - pre-charge contactor, 29 - small-current contactor, 30 - accessory circuit board, 31 - water channel cover plate, 32 - low-voltage signal terminals, 33 - mounting surface of the voltage converter DCDC and OBC integrated module, 34 - mounting surface of the power module IGBT and its drive circuit board and the bus capacitor, 35 - high-voltage interlock terminals. Detailed implementation mode

[0029] In order to make the objectives, technical solutions and advantages of the present utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present utility model and are not used to limit the present utility model.

[0030] The technical solution of the present utility model is as follows: a motor controller, a voltage converter, a high-voltage power distribution and on-vehicle charging integrated device, including a housing 1 that is not sealed at the top and bottom. The top and bottom of the housing 1 are respectively detachably connected to an upper cover plate 12 and a lower cover plate 16 to form a closed device body. The outside of the device body is respectively connected with a fast charge positive and negative terminal 3, a battery positive and negative terminal 4, a three-phase output terminal 5, a DC terminal 6, a first PTC + air conditioner terminal 9, a second PTC terminal 10, an upper-mounted terminal 14, an OBC terminal 8, a low-voltage signal terminal 32, a breather valve, a grounding terminal 13, and at least two water nozzles 7; the inside of the device body is divided into a sealed upper cavity and a lower cavity by at least two horizontal heat dissipation plates. A heat dissipation water channel is arranged between the heat dissipation plates. The upper cavity is provided with a motor controller MCU and a high-voltage power distribution module 24 that are electrically connected to each other. The lower cavity is provided with a voltage converter and an on-vehicle charger OBC two-in-one module; among them, the first PTC + air conditioner terminal 9, the second PTC terminal 10, the upper-mounted terminal 14, the OBC terminal 8, and the low-voltage signal terminal 32 are respectively connected to the high-voltage power distribution module 24 and used as different gear output ports for power distribution to supply power to external devices; the three-phase output terminal 5 is connected to an external motor; the OBC terminal 8 is connected to the N and L ports on the voltage converter DCDC and the OBC two-in-one module 25 with positive and negative wires on the OBC terminal; the DC terminal 1 is connected to the 12V output port of the voltage converter DCDC and the OBC two-in-one module 25 with a copper bar; the fast charge positive and negative terminal 3 and the battery positive and negative terminal 4 are respectively used as a fast charge range extender and a battery input port; the breather valve is communicated with the inside of the device body; the water nozzle 7 is connected to the heat dissipation water channel. Two water nozzles 7 form a group of inlet and outlet ports. Each group of inlet and outlet ports includes an outlet port and an inlet port; the grounding terminal 13 is connected to an external grounding end to play a protective role; the motor controller MCU is electrically connected to each terminal outside the device body.

[0031] The motor controller MCU includes a power module and its drive circuit board, a bus capacitor 20, a control board, and an external interface circuit board 23; among them, the power module and its drive circuit board are installed on the heat dissipation plate, and the 6 DC terminals of the bus capacitor 20 are lapped on the 6 DC terminals of the power module; the three-phase terminals of the power module are connected to the three-phase output terminal 5. The control board is installed on the control board support plate of the housing 1. The signal port of the control board is connected to the drive board on the power module through a signal cable. The control board performs electrical control on the power module. The external interface circuit board 23 is used for electrical connection with each terminal outside the device body.

[0032] A high-current fuse is provided in the circuit formed by the fast charge positive and negative terminal 3.

[0033] The high-voltage power distribution module 24 includes a power distribution terminal block, an accessory circuit board 30, a small-current fuse 27, a high-voltage detector 26, a pre-charge contactor 28, and a small-current contactor 29. Among them, the small-current contactor 29 and the pre-charge contactor 28 are installed on the power distribution terminal block. The bottom of the accessory circuit board 30 is connected to the power distribution terminal block. The first PTC + air-conditioning terminal 9, the second PTC terminal 10, the upper-mounted terminal 14, the OBC terminal 8, and the low-voltage signal terminal 32 are respectively connected to the power distribution terminal block. The top of the accessory circuit board 30 is connected to the small-current fuse 27 and the high-voltage detector 26, and the high-voltage detector 26 is connected to the accessory circuit board 30 through a control line.

[0034] It also includes a first large-current contactor 17, a second large-current contactor 18, and a third large-current contactor 19. The positive terminal of the battery positive and negative terminals is connected to the second large-current contactor 18 through a copper bar. The second large-current contactor 18 is connected to the positive pole of the bus capacitor 20 through a copper bar. The fast-charge positive and negative terminals 3 are connected to the small-current fuse 27 through a copper bar. The small-current fuse 27 is connected to the third large-current contactor 19. The third large-current contactor 19 is connected to the second large-current contactor 18. The second large-current contactor 18 is connected to the positive pole of the battery positive and negative terminals 4 through a copper bar.

[0035] Three control lines are connected from the output terminal of the high-voltage detector 26 and are respectively connected to the input terminal and the output terminal of the first large-current contactor 17, and the input terminal of the third large-current contactor 19. Through this connection method, high-voltage detection is realized.

[0036] A small cover plate 11 detachably connected to the upper cover plate 12 is provided on the upper cover plate 12.

[0037] The control board is connected to the housing 1 through a control board bracket.

[0038] This embodiment adds a high-voltage detection function. Two separate control lines are added to the power distribution board, realizing the timeliness in the action of controlling the main positive and fast-charge contactors to close (detecting a high-voltage signal and then closing the contactor), and at the same time, it can ensure that the fuse in the fast-charge circuit is in a normal state.

[0039] The high-voltage interlock function is added. Three lines are branched from the power distribution board connector (from the output terminal) and are respectively connected to the input terminal and the output terminal of the large-current contactor 1, and the input terminal of the large-current contactor 3. This is the wiring for high-voltage interlock. It is turned to the front through the hole in the middle lower part of the housing 1 and connected to the power distribution board, and is connected in series to ensure the comprehensiveness of the high-voltage interlock function (that is, for the four circuits, if any one of the connectors is disconnected, the whole machine will not be charged).

[0040] The power distribution part connects the wires to the through-wall terminal block through the terminal block connection method and then connects them to the board, enhancing the stability of over-current.

[0041] It should be understood that those of ordinary skill in the art can make improvements or modifications based on the above description, and all such improvements and modifications shall fall within the protection scope of the appended claims of this utility model.

Claims

1. Motor controller, voltage converter, high voltage power distribution and vehicle charging integrated device, characterized in that: The device comprises an upper and lower unsealed shell, the top and bottom of the shell are detachably connected to an upper cover and a lower cover to close to form a closed device body, and the outside of the device body is respectively connected with fast charging positive and negative terminals, battery positive and negative terminals, three-phase output terminals, DC terminals, a first PTC and air conditioning terminals, a second PTC terminal, an upper terminal, an OBC terminal, a low-voltage signal terminal, a breathable valve, a grounding terminal and at least two water spouts; the inside of the device body is divided by at least two horizontal heat dissipation plates to form a closed upper cavity and a lower cavity, and heat dissipation water channels are arranged between the heat dissipation plates, the upper cavity is provided with a motor controller MCU and a high-voltage distribution module electrically connected to each other, and the lower cavity is provided with a voltage converter and an on-board charger OBC two-in-one module; wherein, the first PTC The air-conditioning terminal, the second PTC terminal, the upper terminal, the OBC terminal, and the low-voltage signal terminal are respectively connected to the high-voltage power distribution module as output ports of different gears of power distribution for powering external devices; the three-phase output terminal is connected to the external motor; the voltage converter and the on-board charger OBC two-in-one module are respectively connected to the OBC terminal and the DC terminal; the fast charging positive and negative terminals and the battery positive and negative terminals are respectively used as fast charging range extension and battery input ports; the air valve is connected to the inside of the device body; the water nozzle is connected to the heat dissipation water channel, and the two water nozzles form a group of water inlets and outlets, and each group of water inlets and outlets includes a water outlet and a water inlet; the grounding terminal is connected to the external grounding terminal for protection; the motor controller MCU is electrically connected to each terminal outside the device body.

2. The motor controller, voltage converter, high voltage power distribution and vehicle charging integrated device according to claim 1, characterized in that: The motor controller MCU includes a power module and its driver circuit board, a bus capacitor, a control board and an external interface circuit board; wherein, the power module and its driver circuit board are mounted on a heat sink, and the six DC terminals of the bus capacitor are overlapped on the six DC terminals of the power module; the three-phase terminals of the power module are connected to the three-phase output terminals, the control board is mounted on the control board support plate of the shell, the control board signal port is connected to the driver board on the power module through a signal cable, the control board performs electrical control on the power module, and the external interface circuit board is used for electrical connection with the external terminals of the device body.

3. The motor controller, voltage converter, high voltage power distribution and vehicle charging integrated device according to claim 2, characterized in that: A high-current fuse is provided in the circuit forming the positive and negative terminals of the fast charge.

4. The motor controller, voltage converter, high voltage power distribution and vehicle charging integrated device according to claim 3, characterized in that: The high-voltage power distribution module includes a distribution terminal block, an accessory circuit board, a low-current fuse, a high-voltage detector, a pre-charge contactor and a low-current contactor; wherein, the low-current contactor and the pre-charge contactor are installed on the distribution terminal block, the bottom of the accessory circuit board is connected to the distribution terminal block, the first PTC and the air-conditioning terminal, the second PTC terminal, the upper terminal, the OBC terminal, and the low-voltage signal terminal are respectively connected to the distribution terminal block; the top of the accessory circuit board is connected to the low-current fuse and the high-voltage detector, and the high-voltage detector is connected to the accessory circuit board through a control line.

5. The motor controller, voltage converter, high voltage power distribution and vehicle charging integrated device according to claim 4, characterized in that: It also includes a first high current contactor, a second high current contactor and a third high current contactor. The second high current contactor is connected to the positive pole of the bus capacitor through a copper busbar, the negative pole of the positive and negative terminals of the battery is connected to the first high current contactor through a copper busbar, the first high current contactor is connected to the negative pole of the bus capacitor through a copper busbar, the positive and negative terminals of the fast charge are connected to a small current fuse through a copper busbar, the small current fuse is connected to the third high current contactor, the third high current contactor is connected to the second high current contactor, and the second high current contactor is connected to the positive pole of the positive and negative terminals of the battery through a copper busbar.

6. The motor controller, voltage converter, high voltage power distribution and vehicle charging integrated device according to claim 5, characterized in that: The output end of the high-voltage detector is connected to three control lines, which are respectively connected to the input end and output end of the first high-current contactor and the input end of the third high-current contactor. High-voltage detection is achieved through this connection method.

7. The motor controller, voltage converter, high voltage power distribution and vehicle charging integrated device according to claim 1, characterized in that: The upper cover plate is provided with a small cover plate which is detachably connected with the upper cover plate.

8. The motor controller, voltage converter, high voltage power distribution and vehicle charging integrated device according to claim 2, characterized in that: The control panel is connected to the shell through a control panel bracket.

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