Motor controller, electric drive system comprising same and vehicle
By forming a module installation area on the plastic base and placing the key modules of the motor controller, the problem of too many parts of the motor controller is solved, and cost reduction and production efficiency improvement are achieved.
Patent Information
- Application Number
- CN202421579624.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-07-05
- Publication Date
- 2025-05-30
- Estimated Expiration
- 2034-07-05
AI Technical Summary
Too many parts of the motor controller lead to high hardware costs and assembly costs and low production efficiency.
A multiple module installation area is formed on the integrated plastic base, power module, capacitor module and filter module are placed, and connection and insulation are achieved through conductive terminals and current sensor cores.
It effectively reduces the number of parts of the motor controller, simplifies the structure and assembly process, reduces hardware costs and assembly costs, and improves production efficiency.
Smart Images
Figure CN222928616U_ABST
Abstract
Description
Technical Field
[0001] The utility model belongs to the technical field of motor control, and particularly relates to a motor controller, an electric drive system and a vehicle including the same. Background Art
[0002] The motor controller is an important component of the electric drive system, and is mainly used to supply power to the electric drive system and control the operation of the motor. The motor controller is generally assembled from the following main parts: filter, DC bus capacitor, power module semiconductor, power module cooler, current sensor, AC busbar and PCB control board, etc. In order to facilitate the assembly and layout of the electric drive system, usually, the components of the motor controller need to be assembled together. However, due to the large number of its components, the assembly steps are cumbersome, the installation process is complex, and it is difficult to achieve a reasonable layout, resulting in problems such as high hardware cost, high assembly cost, and low production efficiency. Summary of the Utility Model
[0003] The utility model provides a motor controller, an electric drive system and a vehicle including the same, so as to solve the problems such as high hardware cost, high assembly cost and low production efficiency caused by too many components of the motor controller.
[0004] In order to solve or improve the above technical problems to a certain extent, according to the utility model, a motor controller is provided, including: an integrally formed plastic base, a power module, a capacitor module and a filter module;
[0005] Wherein, the plastic base is formed with a plurality of module placement areas, and the power module, the capacitor module and the filter module are placed in the corresponding module placement areas;
[0006] A plurality of conductive terminals and current sensor cores are correspondingly arranged on the plastic base, and the plurality of conductive terminals pass through the corresponding current sensor cores and are connected to the power module.
[0007] In some embodiments, the conductive terminals and the current sensor cores are integrally formed with the plastic base.
[0008] In some embodiments, the power module and the plastic base enclose a coolant tank, and the coolant tank is for coolant to flow through to cool the power module; an inlet and an outlet are formed on the plastic base, and both the inlet and the outlet are communicated with the coolant tank.
[0009] In some embodiments, a plurality of connection areas are formed between the module placement area corresponding to the power module and the module placement area corresponding to the capacitor module, and baffles are formed between adjacent connection areas.
[0010] In some embodiments, multiple module placement areas are formed on the same side of the plastic base, or multiple module placement areas are formed on opposite sides of the plastic base.
[0011] In some embodiments, the module placement area corresponding to the power module is formed on the first side of the plastic base, and the module placement areas corresponding to the capacitor module and the filtering module are formed on the second side opposite to the first side of the plastic base.
[0012] In some embodiments, the projection of the module placement area corresponding to the capacitor module and / or the filtering module covers part or all of the coolant tank.
[0013] In some embodiments, a control board is further included. The control board is connected to the plastic base and covers at least one of the power module, the capacitor module, and the filtering module.
[0014] According to another aspect of the present invention, an electric drive system is provided, including the motor controller according to any one of the above embodiments.
[0015] According to another aspect of the present invention, a vehicle is provided, including the electric drive system according to the above embodiment.
[0016] The motor controller of the present utility model realizes functions such as installation, positioning, and insulation of multiple modules of the motor controller by forming multiple module placement areas on an integrally formed plastic base, effectively reducing the number of components of the motor controller, simplifying the structure and assembly process of the motor controller, and reducing the hardware cost and assembly cost of the motor controller. Multiple conductive terminals and current sensor cores are integrally injection-molded with the plastic base. While further simplifying the process flow, on the one hand, the magnetic field formed when current flows through the conductive terminals can be collected by the current sensor core, and then the magnitude of the current flowing through the conductive terminals can be calculated through this magnetic field. On the other hand, the current sensor core can shield the magnetic field generated by external current to avoid the situation of low current calculation accuracy caused by the interference of external magnetic fields.
[0017] The above description is only an overview of the technical solution of the present utility model. In order to be able to understand the technical means of the present utility model more clearly, it can be implemented according to the content of the specification. And in order to make the above and other purposes, features, and advantages of the present utility model more obvious and understandable, the following specific preferred embodiments are given and described in detail in conjunction with the drawings as follows. BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Figure 1 is an exploded structural schematic diagram of a motor controller according to an embodiment of the present utility model;
[0019] Figure 2Schematic cross-sectional structure diagram of the motor controller according to another embodiment of the present utility model.
[0020]
Symbol Explanation
[0021] 10. Plastic base
[0022] 100. Module placement area
[0023] 1000. First module placement area
[0024] 1001. Second module placement area
[0025] 1002. Third module placement area
[0026] 101. Connection area
[0027] 1010. Baffle
[0028] 20. Power module
[0029] 30. Capacitor module
[0030] 40. Filter module
[0031] 50. Conductive terminal
[0032] 60. Current sensor core
[0033] 70. Coolant tank
[0034] 80. Control board Detailed Implementation Manner
[0035] To further elaborate on the technical means and effects adopted by the present utility model to achieve the intended utility model purpose, the following, in conjunction with the accompanying drawings and preferred embodiments, details the specific implementation manners and effects of a motor controller, an electric drive system including the same, and a vehicle proposed according to the present utility model as follows.
[0036] According to an embodiment of the present utility model, a motor controller is provided, as Figure 1 shown, including: a plastic base 10, a power module 20, a capacitor module 30, and a filter module 40.
[0037] Among them, the plastic base 10 is an integrally formed structure, and its integral formation can be achieved through injection molding processes, compression molding processes, etc. The present utility model is not limited to specific preparation processes.
[0038] Multiple module placement areas 100 are formed on the plastic base 10, and the power module 20, the capacitor module 30, and the filter module 40 are respectively placed in their corresponding module placement areas 100.
[0039] Optionally, each module placement area 100 is formed into a groove structure, and each groove structure matches the outer shape structure of its corresponding module.
[0040] By forming a plurality of module placement areas 100 on the plastic base 10, functions such as installation, positioning, and insulation of multiple modules of the motor controller are realized, effectively reducing the number of components of the motor controller, simplifying the structure and assembly process of the motor controller, and reducing the hardware cost and assembly cost of the motor controller.
[0041] In one embodiment, as Figure 1 shown, a first module placement area 1000, a second module placement area 1001, and a third module placement area 1002 are formed on the plastic base 10.
[0042] Among them, the power module 20 is placed in the first module placement area 1000, the capacitor module 30 is placed in the second module placement area 1001, and the filter module 40 is placed in the third module placement area 1002.
[0043] In this embodiment, after the capacitor module 30 is placed in the corresponding module placement area 100 (i.e., the second module placement area 1001), it can be fixed by means of glue potting or screws, etc.
[0044] After the filter module 40 is placed in the corresponding module placement area 100 (i.e., the third module placement area 1002), it can also be fixed by means of glue potting or screws, etc.
[0045] In one embodiment, as Figure 1 and Figure 2 shown, after the power module 20 is placed in the corresponding module placement area 100 (i.e., the first module placement area 1000), a coolant tank 70 surrounded by the power module 20 and the plastic base 10 is formed in the first module placement area 1000. Coolant flows through the coolant tank 70 to cool the power module 20 through the coolant.
[0046] In this embodiment, by cooperating the power module 20 and the plastic base 10 to form the coolant tank 70, a liquid cooling plate made of plastic is formed, solving the problem that the liquid cooling plate made of metal is prone to bubbles, shrinkage cavities, cracks, etc. during the casting process, resulting in liquid leakage.
[0047] Optionally, a liquid inlet (not shown in the figure) and a liquid outlet (not shown in the figure) are formed on the plastic base 10. Both the liquid inlet and the liquid outlet are connected to the coolant tank 70 and are connected to a cooling device outside the motor controller (such as the cooling device of the electric drive system), so that the coolant in the coolant tank 70 can circulate to achieve the purpose of continuous cooling.
[0048] In one embodiment, asFigure 1 As shown, a plurality of connection areas 101 are formed between the module placement area 100 corresponding to the power module 20 (i.e., the first module placement area 1000) and the module placement area 100 corresponding to the capacitor module 30 (i.e., the second module placement area 1001), and baffles 1010 are formed between adjacent connection areas 101.
[0049] In this embodiment, the plastic base 10 forms a plurality of connection areas 101 between the first module placement area 1000 and the second module placement area 1001, such that a plurality of connection terminals of the power module 20 and a plurality of connection terminals of the capacitor module 30 are electrically connected in the plurality of connection areas 101 respectively, and a baffle 1010 made of plastic is formed between every two adjacent connection areas 101. Insulation between the plurality of connection terminals is achieved through the baffle 1010 made of plastic, such that there is no need to sleeve insulating materials on the connection terminals for insulation, reducing the number of components of the motor controller and simplifying the assembly process of the motor controller.
[0050] In one embodiment, the filtering module 40 is an electrical filter, which includes a capacitor. One or both stages of the capacitor are connected to the input DC bus to filter the input DC current. The capacitor module 30 is a DC bus capacitor, which includes a capacitor with a relatively large capacitance value (usually exceeding 1 uF), and both ends of the capacitor are connected to the DC bus. The power module 20 is a power semiconductor module for converting direct current into alternating current. The conductive terminal 50 is an AC output busbar, and both ends thereof are respectively connected to the power semiconductor module and the motor to provide alternating current for the motor.
[0051] As Figure 1 and Figure 2 shown, based on the requirements of different layouts of the motor controller, the plurality of module placement areas 100 formed by the plastic base 10 can be formed on the same side of the plastic base 10, or can be formed on opposite sides of the plastic base 10.
[0052] As Figure 2 shown, when the plurality of module placement areas 100 are formed on opposite sides of the plastic base 10, among them, the module placement area 100 corresponding to the power module 20 (i.e., the first module placement area 1000) is formed on the first side of the plastic base 10, and the module placement areas 100 corresponding to the capacitor module 30 and the filtering module 40 (i.e., the second module placement area 1001 and the third module placement area 1002) are formed on the second side opposite to the first side of the plastic base 10.
[0053] Optionally, when a plurality of module placement areas 100 are formed on two opposite surfaces of the plastic base 10, the projections of the corresponding module placement areas 100 of the capacitor module 30 and / or the filter module 40 (i.e., the second module placement area 1001 and the third module placement area 1002) cover part or all of the coolant tank 70. As a result, the coolant tank 70 can cool the power module 20 while also cooling the capacitor module 30 and / or the filter module 40.
[0054] As Figure 1 shown, a plurality of conductive terminals 50 and a plurality of current sensor cores 60 are also provided on the plastic base 10, and the positions of the plurality of conductive terminals 50 and the plurality of current sensor cores 60 correspond to each other. The plurality of conductive terminals 50 pass through the corresponding current sensor cores 60 and are connected to the power module 20.
[0055] By sleeving the current sensor cores 60 on the plurality of conductive terminals 50, on the one hand, the current sensor cores 60 can collect the magnetic field formed when the current flows through the conductive terminals 50, and then calculate the magnitude of the current flowing through the conductive terminals 50 through this magnetic field. On the other hand, the current sensor cores 60 can shield the magnetic field generated by external currents to avoid the situation where the accuracy of current calculation is low due to the interference of external magnetic fields.
[0056] The plurality of conductive terminals 50 are arranged at intervals, that is, a part of the plastic base 10 is provided between two adjacent conductive terminals 50 to achieve insulation between the conductive terminals 50, eliminating the need to sleeve insulating materials on the conductive terminals 50 for insulation, reducing the number of components of the motor controller, and simplifying the assembly process of the motor controller.
[0057] The plurality of current sensors are arranged corresponding to the plurality of conductive terminals 50, and a part of the plastic base 10 is also provided between two adjacent current sensor cores 60.
[0058] Optionally, the conductive terminals 50 and the current sensor cores 60 can be pre-installed on the plastic base 10 by means such as mounting or overmolding to simplify the subsequent assembly process of the motor controller.
[0059] Preferably, the conductive terminals 50 and the current sensor cores 60 are integrally injection-molded with the plastic base 10.
[0060] As Figure 1 and Figure 2 shown, the motor controller further includes a control board 80, which is connected to the plastic base 10 and covers at least one of the power module 20, the capacitor module 30, and the filter module 40.
[0061] Optionally, the control board 80 is a PCB board.
[0062] Another embodiment of the present utility model provides an electric drive system, including the motor controller of any one of the above embodiments.
[0063] Optionally, the electric drive system further includes a motor and a cooling device. After converting the direct current output by the power supply module (such as a power battery module) into alternating current, the motor controller delivers it to the motor through conductive terminals to supply power to the motor. The coolant tank of the motor controller is connected to the cooling device of the electric drive system so that the coolant in the coolant tank can circulate.
[0064] Another embodiment of the present utility model provides a vehicle, which includes the electric drive system of any one of the above embodiments.
[0065] The motor controller of the present utility model forms multiple module placement areas on an integrally formed plastic base to achieve functions such as installation, positioning, and insulation of multiple modules of the motor controller, effectively reducing the number of components of the motor controller, simplifying the structure and assembly process of the motor controller, and reducing the hardware cost and assembly cost of the motor controller. Multiple conductive terminals and current sensor cores are integrally injection-molded with the plastic base. While further simplifying the process flow, on the one hand, the current sensor core can collect the magnetic field formed when the current flows through the conductive terminals, and then calculate the magnitude of the current flowing through the conductive terminals through this magnetic field. On the other hand, the current sensor core can shield the magnetic field generated by external currents to avoid the situation of low current calculation accuracy caused by the interference of external magnetic fields.
[0066] The above are only the preferred embodiments of the present utility model and do not impose any formal limitations on the present utility model. Although the present utility model has been disclosed above with preferred embodiments, it is not intended to limit the present utility model. Any person skilled in the art can make some changes or modifications to equivalent embodiments by using the disclosed technical content within the scope of the technical solution of the present utility model. However, as long as it does not depart from the content of the technical solution of the present utility model, any simple modification, equivalent change, and modification made to the above embodiments according to the technical essence of the present utility model still fall within the scope of the technical solution of the present utility model.
Claims
1. A motor controller, characterized in that: include: One-piece plastic base, power module, capacitor module and filter module; Wherein, the plastic base is formed with a plurality of module placement areas, and the power module, the capacitor module and the filter module are placed in the corresponding module placement areas; A plurality of conductive terminals and a current sensor magnetic core are correspondingly arranged on the plastic base, and the plurality of conductive terminals are connected to the power module after passing through the corresponding current sensor magnetic core.
2. The motor controller according to claim 1, characterized in that: The conductive terminal and the current sensor magnetic core are integrally formed with the plastic base.
3. The motor controller according to claim 1, characterized in that: The power module and the plastic base together form a cooling liquid tank, through which coolant flows to cool the power module; a liquid inlet and a liquid outlet are formed on the plastic base, and both the liquid inlet and the liquid outlet are connected to the cooling liquid tank.
4. The motor controller according to claim 1, characterized in that: A plurality of connection areas are formed between the module placement area corresponding to the power module and the module placement area corresponding to the capacitor module, and baffles are formed between adjacent connection areas.
5. The motor controller according to claim 1, characterized in that: A plurality of module placement areas are formed on the same side of the plastic base, or a plurality of module placement areas are formed on two opposite sides of the plastic base.
6. The motor controller according to claim 5, characterized in that: The module placement area corresponding to the power module is formed on a first side of the plastic base, and the module placement areas corresponding to the capacitor module and the filter module are formed on a second side of the plastic base opposite to the first side.
7. The motor controller according to claim 3, characterized in that: The projection of the module placement area corresponding to the capacitor module and / or the filter module covers part or all of the cooling liquid tank.
8. The motor controller according to claim 1, characterized in that: It also includes a control board, which is connected to the plastic base and covers at least one of the power module, the capacitor module and the filter module.
9. An electric drive system, characterized in that: The motor controller comprises the motor controller as claimed in any one of claims 1 to 8.
10. A vehicle, characterized in that: Includes the electric drive system as described in claim 9.