Motor controller upper box body structure, motor controller and vehicle

Abstract

The utility model relates to the technical field of motor controllers of automobiles, and discloses a motor controller upper box body structure, a motor controller and a vehicle, the motor controller upper box body structure comprises an upper cover body, the surface of the upper cover body is at least provided with two window parts, and the at least two window parts comprise function holes penetrating through the upper cover body; reinforcing ribs are arranged on the surface of the upper cover body and connected with the two window portions, and the upper cover body is designed to be of a step structure. The problem that in the prior art, a mounting opening and an access opening are formed in an upper box body structure, so that the strength of the box body structure is reduced is solved.

Description

Technical Field

[0001] The present application relates to the technical field of motor controllers for vehicles, and specifically relates to an upper box structure of a motor controller, a motor controller, and a vehicle. Background Art

[0002] With the development of new energy vehicles, the electric drive system has also been continuously developed and improved. The motor controller is an important component in the electric drive system. It controls the operation of the electric drive system and is the most core component. The housing of the motor controller usually adopts a box structure, and an installation space is formed inside the box structure. The control circuit formed by the controller components of the motor controller is installed in the installation space, so as to realize the function of supporting and wrapping the circuit components through the box structure. There are many components in the installation space inside the box structure, and it is required that its assembly and maintenance are convenient. Therefore, installation ports and maintenance ports are provided.

[0003] Generally, the installation ports and maintenance ports are arranged on the side of the box structure. Such arranged installation ports (maintenance ports) cause operators to install and maintain from the side, increasing the operation difficulty and the overall height of the controller. If installation ports and maintenance ports are arranged on the top of the box structure, it will cause more openings in the upper box structure and reduce the structural strength, thereby reducing the NVH performance (which refers to noise, vibration, and harshness performance).

[0004] Therefore, the existing situation and technology still need to be improved and developed. Summary of the Utility Model

[0005] To solve the above problems, the purpose of the present application is to provide an upper box structure of a motor controller, a motor controller, and a vehicle, so as to solve the problem that opening installation ports and maintenance ports on the upper box structure in the prior art will reduce the structural strength of the box structure.

[0006] The technical solution of the present utility model is as follows:

[0007] In the first aspect, the present application proposes an upper box structure of a motor controller, including an upper cover body, wherein at least two window portions are provided on the surface of the upper cover body, and at least two window portions both include functional holes penetrating the upper cover body;

[0008] Reinforcing ribs are provided on the surface of the upper cover body, and the reinforcing ribs connect at least two window portions.

[0009] According to the above technical means, although setting at least two functional holes on the upper cover body facilitates maintenance, it will reduce the structural strength of the upper box body structure, thereby reducing the NVH performance of the box body structure. However, by arranging reinforcing ribs between at least two window parts, connecting the reinforcing ribs to the outer walls of the upper cover body and the window parts, the edges of the functional holes are strengthened, and the structural strength of the entire upper box body structure is improved, thereby improving the NVH performance of the upper box body structure and reducing noise.

[0010] Combined with the first aspect, in some implementation manners of the first aspect, the wall thickness of the reinforcing rib is greater than the wall thickness of the upper cover body.

[0011] According to the above technical means, the wall thickness of the reinforcing rib is set to be relatively thick, greater than the thickness of the upper cover body. The reinforcing rib continuously penetrates through and is connected to the outer walls of the upper cover body and the window part, so that the structural strength of the entire upper box body structure is further enhanced, and the NVH performance of the upper box body structure is improved.

[0012] Combined with the first aspect, in some implementation manners of the first aspect, a box body main body convex part is further arranged on the surface of the upper cover body, and the reinforcing rib continuously penetrates through the box body main body convex part.

[0013] According to the above technical means, the box body main body convex part and the upper cover body are connected together through the continuously penetrating reinforcing rib, and are matched so that the structural strengthening parts on the upper cover body are connected and cooperate to bear force, enhancing the structural strength of the upper box body structure.

[0014] Combined with the first aspect, in some implementation manners of the first aspect, the box body main body convex part includes: a plurality of convex surfaces, and there is a height difference between the plurality of convex surfaces to form a stepped distribution.

[0015] According to the above technical means, the box body main body convex part is set to be in a stepped distribution, so that the upper box body structure forms a multi-level structure, which can further improve the NVH performance of the box body and reduce noise.

[0016] Combined with the first aspect, in some implementation manners of the first aspect, the plurality of convex surfaces include: a first convex surface;

[0017] a second convex surface, the second convex surface is concave with respect to the first convex surface and is located on one side of the first convex surface;

[0018] At least two window parts are arranged on both sides of at least one first convex surface, and the reinforcing rib continuously penetrates through the first convex surface.

[0019] According to the above technical means, the upper cover body is designed into a stepped structure, and the window parts are located on both sides of the first convex surface, so that the functional holes are not too concentrated on the upper cover body, and the interval distance between two functional holes is relatively large, thereby avoiding a large local opening area on the upper cover body and ensuring structural stability.

[0020] In combination with the first aspect, in certain implementations of the first aspect, the multiple raised surfaces further include:

[0021] A third raised surface that is concave below the second raised surface and is connected to the second raised surface and the first raised surface;

[0022] And a fourth raised surface that is concave below the third raised surface.

[0023] According to the above technical means, a four-layer raised structure is formed between the raised portion of the box body and the upper cover body, effectively increasing the structural strength of the raised portion of the box body. The raised portion of the box body, as the main part of the upper box structure, has stable support strength, further improving the NVH performance of the box.

[0024] In combination with the first aspect, in certain implementations of the first aspect, at least two functional holes include a wiring harness installation port, a fuse maintenance port, and / or a busbar installation port.

[0025] According to the above technical means, by opening a wiring harness installation port, a fuse maintenance port, and / or a busbar installation port on the surface of the upper cover body, operators can directly perform installation and maintenance operations above the motor controller, making the installation and maintenance more convenient.

[0026] In combination with the first aspect, in certain implementations of the first aspect, the functional holes include: 2 busbar installation ports, 1 wiring harness installation port, and 1 fuse maintenance port;

[0027] There is a strengthened connection between the window portion provided with the wiring harness installation port and the window portion provided with the fuse maintenance port.

[0028] According to the above technical means, the busbar installation ports, the wiring harness installation port, and the fuse maintenance port are evenly distributed on the upper cover plate. After connecting the window portions through the reinforcing ribs, operators can directly perform relatively complete installation and maintenance operations above the motor controller, and at the same time, the structural strength of the upper box structure can be ensured to improve the NVH performance of the box.

[0029] In combination with the first aspect, in certain implementations of the first aspect, the inner wall of the functional hole extends a predetermined length away from the surface of the window portion to form a baffle rib;

[0030] The baffle rib cooperates with the extended baffle to form a fence, and the fence is used to enclose an object-blocking channel communicating with the functional hole inside the motor controller.

[0031] According to the above technical means, through the baffle ribs or the object blocking channels, a section of area can be separated in the installation cavity, so that the operator or the tool can only operate within the area corresponding to the function port, thereby avoiding the bolts from falling into the motor controller during installation or maintenance and contacting the electrical components to cause a short circuit, and improving the safety of its assembly and maintenance.

[0032] In a second aspect, the present utility model further provides a motor controller, which includes: a lower box body structure and the above-mentioned motor controller upper box body structure, and the motor controller upper box body structure is connected to the lower box body structure to form an installation space for installing controller components.

[0033] In a third aspect, the present utility model further provides a vehicle, including: a vehicle body and the above-mentioned motor controller.

[0034] The beneficial effects of a motor controller upper box body structure, a motor controller and a vehicle provided by the present utility model are at least as follows:

[0035] (1) By providing at least two window parts on the upper cover body, the tool can extend into the internal installation space of the motor controller through the function holes on the window parts to perform installation and maintenance operations respectively. The operator can perform installation and maintenance directly above the motor controller, reducing the operation difficulty of the operator and making the installation and maintenance process of the motor controller more convenient.

[0036] (2) By opening the function holes on the top of the upper box body structure, compared with opening the function holes on the side of the motor controller, the height space occupied by the function holes can be reduced, thereby reducing the overall height of the motor controller.

[0037] (3) By arranging reinforcing ribs between at least two window parts, the reinforcing ribs connect the upper cover body and the outer walls of the window parts, strengthening the edge of the function hole, improving the structural strength of the entire upper box body structure, and setting the upper cover plate into a stepped structure, thereby improving the NVH performance of the upper box body structure and reducing noise. Description of the Drawings

[0038] Figure 1 It is a schematic structural view of the motor controller upper box body structure of this embodiment from the front perspective;

[0039] Figure 2 It is a schematic structural view of the motor controller upper box body structure of this embodiment from the back perspective;

[0040] Figure 3 It is a cross-sectional view of the bolt installation position of the motor controller of this embodiment.

[0041] Reference numerals in the figure: 100 - upper cover body; 200 - window part; 210 - raised edge; 220 - functional hole; 221 - wiring harness installation port; 222 - fuse maintenance port; 223 - busbar installation port; 230 - baffle rib; 300 - reinforcing rib; 400 - convex part of the box body; 410 - first convex surface; 420 - second convex surface; 430 - third convex surface; 440 - fourth convex surface; 500 - grid reinforcing rib; 600 - lower box body structure; 700 - busbar connector, 710 - extended baffle; 711 - object blocking channel; 720 - busbar; 800 - bolt. Detailed implementation manners

[0042] The following will describe the implementation manners of the present application with reference to the accompanying drawings and preferred embodiments. Those skilled in the art can easily understand other advantages and effects of the present application from the content disclosed in this specification. The present application can also be implemented or applied through other different specific implementation manners. Various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present application. It should be understood that the preferred embodiments are only for explaining the present application, rather than for limiting the protection scope of the present application.

[0043] Installing the installation port and the maintenance port on the side of the box body structure of the motor controller is not only inconvenient for installing and maintaining the electrical components in the installation space inside the motor controller. Moreover, setting the installation port and the maintenance port on the side of the motor controller will occupy the height space, thereby increasing the overall height of the motor controller. In addition, due to the particularity of the electric drive system assembly, its noise is higher than that of the traditional power system, so high requirements are placed on the NVH performance of the box body structure of the motor controller. If installation holes and maintenance holes are opened on the upper box body structure, it will lead to a reduction in structural strength, an increase in vibration during operation, an increase in noise, and the box body is convenient for assembly and reduces the overall height of the controller assembly. Based on the above disadvantages, the following embodiments are proposed in this solution to solve the above problems.

[0044] Embodiment 1

[0045] This embodiment proposes an upper box body structure of a motor controller, which is used to cooperate with the lower box body structure to form an installation space inside the motor controller for installing electrical components. As Figure 1As shown in the figure, the upper box structure of the motor controller mainly includes an upper cover body 100. On the surface of the upper cover body 100, at least two window parts 200 are provided. Each window part 200 may include a raised edge 210 and a functional hole 220 penetrating the upper cover body 100. The functional hole 220 is located in the area surrounded by the raised edge 210. Through the functional hole 220, it communicates with the installation space, enabling the operator or operating tool to enter the installation space from above the motor controller through the functional hole 220, so as to install or repair the electrical components in the installation space, thus facilitating the operation of the operator. Reinforcing ribs 300 are provided on the surface of the upper cover body 100. The reinforcing ribs 300 are provided on the upper cover body 100 and connect the two window parts 200, thereby enhancing the structural strength of the upper cover body 100. In a specific structure, both ends of the reinforcing rib 300 are respectively connected to the outer walls of the two raised edges 210, and both ends of the reinforcing rib are only slightly lower than the wall height of the raised edge 210, so as not to interfere with the functional hole 220 surrounded by the raised edge 210. The raised edge 210 not only plays a protective role for the functional hole 220 therein, increasing the structural strength at the edge of the functional hole 220. Moreover, after being connected to the reinforcing rib 300, an intersecting raised structure is formed on the surface of the upper cover body 100, enhancing the structural strength of the entire upper box structure.

[0046] As Figure 1 shown, further, in this embodiment, the wall thickness of the reinforcing rib 300 is greater than the wall thickness of the main body of the upper cover body 100. By setting the wall thickness of the reinforcing rib 300 to be relatively thick, the reinforcing rib 300 continuously penetrates the upper cover body to achieve stable connection with the outer wall of the window part 200, thereby further enhancing the structural strength of the entire upper box structure and improving the NVH performance of the upper box structure.

[0047] As Figure 1 shown, further, on the surface of the upper cover body 100 in this embodiment, a box body main body raised part 400 is also provided. The box body main body raised part 400 is formed by a partial area of the upper cover body 100 protruding upward. Through the box body main body raised part 400, a stepped structure is formed on the surface of the upper cover body 100, enhancing the structural strength of the entire upper box structure. For the convenience of structural description, the direction of the long side of the entire upper box structure is taken as the length direction, and the direction perpendicular to the length direction on the horizontal plane is taken as the width direction. At least two window parts 200 may be distributed along the length direction, and at least two window parts 200 are respectively connected to the box body main body raised part 400 through the reinforcing rib 300. Thus, the entire reinforcing rib 300 can completely span the box body main body raised part 400 to improve the stiffness of the upper box structure. After the reinforcing rib 300 spans the box body main body raised part 400 and both ends are respectively connected to two separately arranged window parts 200, the structural strength of the upper box structure can be improved.

[0048] As Figure 1 andFigure 2 As shown, further, the reinforcing rib 300 continuously penetrates through the raised portion 400 of the box body between the two window portions 200. The reinforcing rib 300 is continuously and uninterruptedly formed on the upper cover body, and can be formed on both the upper and lower surfaces of the upper cover body 100, so as to strengthen the structure of the upper cover body 100. Moreover, the reinforcing rib 300 penetrates through the raised portion 400 of the box body, thereby connecting the raised portion 400 of the box body, the upper cover body 100 and the outer wall of the window portion 200 together, and matching to connect the structural reinforcement members on the upper cover body 100 to bear force together, enhancing the structural strength of the upper box structure.

[0049] As Figure 1 shown, further, the raised portion 400 of the box body may include: a plurality of raised surfaces, and there is a height difference between the plurality of raised surfaces to form a stepped distribution. The raised portion 400 of the box body is arranged in a stepped distribution, so that the upper box structure forms a multi-level structure, which not only increases the strength of the upper box body, but also reduces the sound radiation area, and can further improve the NVH performance of the box body and reduce noise. The plurality of raised surfaces of the raised portion 400 of the box body in this embodiment mainly include: at least one first raised surface 410 and at least one second raised surface 420. The first raised surface 410 and the second raised surface 420 may be surfaces formed by protruding upward from the upper surface of the upper cover body 100. The height of the first raised surface 410 is the highest, and the second raised surface 420 is recessed below the first raised surface 410 and is located on one side of the length direction of the first raised surface 410. The two window portions 200 are arranged on both sides of the length direction of at least one of the first raised surfaces 410, and the reinforcing rib 300 continuously penetrates through the first raised surface 410. By arranging at least two window portions 200 on different raised surfaces on both sides of the first raised surface 410 respectively, the functional holes 220 are not too concentrated on the upper cover body 100, and the interval distance between the two functional holes 220 is relatively large, thereby avoiding a large local opening area on the upper cover body 100 and ensuring the structural stability.

[0050] In this embodiment, the multiple convex surfaces of the convex portion 400 of the box body may further include: a third convex surface 430 and a fourth convex surface 440. The third convex surface 430 may be a surface formed by protruding upward from the upper surface of the upper cover body 100, and the fourth convex surface 440 may be the upper surface of the upper cover body 100. The third convex surface 430 is concave with respect to the second convex surface 420 and is connected to the second convex surface 420 and the first convex surface 410. The third convex surface 430 is located on one side in the width direction of the second convex surfaces 420 on both sides. The fourth convex surface 440 is concave with respect to the third convex surface 430 and is respectively located on one side in the width direction of the third convex surface 430. The height differences between the adjacent heights of the four steps are all relatively small. Forming a four-layer convex structure with the convex portion 400 of the box body and the upper cover body 100 effectively increases the structural strength of the convex portion 400 of the box body. Making the convex portion 400 of the box body have stable support strength as the main part of the upper box body structure further improves the NVH performance of the box body and provides more stable support and protection for the controller components in the installation space.

[0051] As Figure 2 shown, and grid-shaped reinforcing ribs 500 are provided on the lower surface (inner wall) of the convex portion 400 of the box body and the upper cover body 100, and reinforcing ribs 300 are provided between the two window portions 200 to cooperate, further improving the NVH performance of the upper box body structure and reducing noise.

[0052] As Figure 1 、 Figure 3 shown, further, at least two functional holes 220 in this embodiment may include a wire harness installation port 221, a fuse maintenance port 222, and / or a busbar installation port 223. The wire harness installation port 221 is used for an operator to install a cable harness into the installation space; the fuse maintenance port 222 is used for an operator to maintain and replace the fuse in the installation space; the busbar installation port 223 is used for an operator to screw the bolts 800 located in the installation space, thereby connecting the three-phase power busbar to the busbar connector 700. Different functions can be achieved through the functional holes 220. The multiple functional holes 220 may be multiple of one type among the wire harness installation port 221, the fuse maintenance port 222, and the busbar installation port 223. It can also be a combination of multiple functional holes 220 with different functions. Therefore, by opening the wire harness installation port 221, the fuse maintenance port 222, and / or the busbar installation port 223 on the surface of the upper cover body 100, an operator can directly perform installation and maintenance operations above the motor controller, making the installation and maintenance more convenient.

[0053] As Figure 2 、 Figure 3As shown, further, on the surface of the inner wall of the functional hole 220 in this embodiment, a baffle rib 230 is formed by extending a predetermined length away from the window portion 200. The baffle rib 230 can be formed by extending in the directions towards the copper bar installation opening 223 and the fuse maintenance opening 222. The inner wall of the baffle rib 230 and the inner wall of the corresponding window portion 200 are the same inner wall. Since the baffle rib 230 does not need to bear weight, in order to improve the castability of the upper box body structure, the wall thickness of the baffle rib 230 is relatively thin, and it is sufficient to be greater than or equal to 2 mm. The structure of the baffle rib 230 is described by taking the copper bar installation opening 223 as an example. The baffle rib 230 is formed by extending downward on the inner wall of the copper bar installation opening 223. The copper bar connector 700 includes an extended baffle 710 and a copper bar 720 arranged in the installation space. The extended baffle 710 is located below the baffle rib 230. The baffle rib 230 and the extended baffle 710 cooperate to form a fence, and the fence is used to enclose an object-blocking channel 711 communicating with the functional hole 220 inside the motor controller. When operating inside the copper bar installation opening 223, the bolt 800 is placed into the interior of the motor controller through the copper bar installation opening 223 and is installed on the copper bar 720 in the object-blocking channel 711. During the installation process, through the baffle rib 230 and the object-blocking channel 711, a section of area can be separated in the installation cavity, so that the operator or tool can only operate within the area corresponding to the functional opening, thereby preventing the bolt 800 from falling into the interior of the motor controller and contacting the electrical components during installation or maintenance, which may cause a short circuit, and improving the safety of its assembly and maintenance.

[0054] Embodiment 2

[0055] As Figure 1 、 Figure 3 As shown, this embodiment provides a motor controller, which includes: a lower box body structure 600 and the above-mentioned upper box body structure of the motor controller. The upper box body structure of the motor controller is connected to the lower box body structure 600 to form an installation space for installing controller components.

[0056] The motor controller of this embodiment adopts an upper box structure, which not only facilitates the assembly and maintenance of electrical components inside the motor controller, but also can reduce the overall height of the controller assembly and optimize the structure of the motor controller. The copper busbar installation opening 223, the fuse maintenance opening 222, and the wire harness installation opening 221 are all arranged at the top of the upper box structure. Baffle ribs 230 are extended and formed in the function holes 220 to prevent bolts 800 from falling into the controller during installation or maintenance and contacting electrical components, causing a short circuit, thereby improving its assembly and maintenance performance. Since the occupied area of the function holes 220 opened at the top is relatively large, which will reduce the NVH performance of the upper box structure, in addition to setting grid stiffeners 500 on the lower surface (inner wall) of the upper cover 100, stiffeners 300 are also arranged between two window parts 200 for connection, and the convex part 400 of the box body is designed to be stepped to improve the NVH performance of the upper box structure and reduce noise.

[0057] Embodiment III

[0058] The present utility model also provides a vehicle, including: a vehicle body and the motor controller as described above.

[0059] In summary, the present application provides an upper box structure of a motor controller, a motor controller, and a vehicle. By providing at least two window parts on the upper cover, the function holes on the window parts can allow tools to extend into the internal installation space of the motor controller for installation and maintenance operations respectively. The operator can perform installation and maintenance directly from the upper part of the motor controller, reducing the operation difficulty of the operator and making the installation and maintenance process of the motor controller more convenient. Baffle ribs are extended and formed in the function holes to prevent bolts from falling into the controller during installation or maintenance and contacting electrical components, causing a short circuit, thereby improving its assembly and maintenance performance. By opening function holes on the upper box structure, compared with opening function holes on the side of the motor controller, the occupied area of the function holes can be reduced, thereby reducing the overall height of the motor controller. By arranging transverse stiffeners between at least two window parts, the stiffeners connect the upper cover and the outer walls of the window parts, strengthening the edge of the function holes and improving the structural strength of the entire upper box structure. By setting the convex part of the box body to form a stepped structure on the upper cover, and the convex part of the box body is set to an uneven surface to form a stepped shape, and cooperating with the grid stiffeners provided on the lower surface (inner wall) of the upper cover and the stiffeners arranged between two window parts, the NVH performance of the upper box structure is improved and the noise is reduced.

[0060] The above embodiments are only preferred embodiments given to fully illustrate the present application, and the protection scope of the present application is not limited thereto. Equivalent substitutions or transformations made by those skilled in the art on the basis of the present application are all within the protection scope of the present application.

Claims

1. A motor controller upper box structure, comprising: The upper cover body is characterized in that at least two window portions are provided on the surface of the upper cover body, and at least two of the window portions each include a functional hole penetrating the upper cover body; A reinforcing rib is provided on the surface of the upper cover body, and the reinforcing rib connects at least two of the window portions; A box body convex portion is arranged on the surface of the upper cover body, and the reinforcing rib continuously passes through the box body convex portion; The raised portion of the box body includes: a plurality of raised surfaces, wherein the plurality of raised surfaces have height differences to form a stepped distribution; The plurality of raised surfaces include: at least one first raised surface; at least one second convex surface, the second convex surface being concave below the first convex surface and located on one side of the first convex surface; At least two of the window portions are arranged on both sides of at least one of the first raised surfaces, and the reinforcing ribs continuously penetrate the first raised surface; a third convex surface, the third convex surface being concave below the second convex surface and connected to the second convex surface and the first convex surface; and a fourth convex surface, wherein the fourth convex surface is concave below the third convex surface.

2. The upper box structure of the motor controller according to claim 1, characterized in that: The wall thickness of the reinforcing rib is greater than the wall thickness of the upper cover body.

3. The upper box structure of the motor controller according to any one of claims 1-2, characterized in that: At least two of the functional holes include a wiring harness installation port, a fuse inspection port and / or a copper busbar installation port.

4. The upper box structure of the motor controller according to claim 3 is characterized in that: The inner wall of the functional hole extends away from the surface of the window portion by a predetermined length to form a baffle rib; The baffle ribs cooperate with the extended baffle to form a fence, and the fence is used to enclose a blocking channel in the motor controller that is connected to the functional hole.

5. A motor controller, characterized in that: It comprises: a lower box structure and an upper box structure of a motor controller as described in any one of claims 1 to 4, wherein the upper box structure of the motor controller is connected to the lower box structure to form an installation space, and the installation space is used to install controller components.

6. A vehicle, characterized in that: include: A vehicle body and a motor controller as claimed in claim 5.

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