Motor controller of single motor and power assembly thereof

Abstract

The utility model provides a power assembly used for a motor controller of a single motor, comprising a capacitor housing in which a DC capacitor is arranged; the power module is arranged at the top of the DC capacitor, the power module comprises an AC current terminal and a signal terminal, and the AC current terminal and the signal terminal extend towards the two sides of the capacitor shell respectively; the AC switching copper bar and the AC current terminal are arranged on the same side, and the AC switching copper bar is used for connecting a motor end AC copper bar of the motor and the AC current terminal of the power module; the AC switching copper bar is detachably connected to the side surface of the capacitor shell through a copper bar plastic shell; and the first cooling water channel is arranged on the upper surface of the power module and is used for carrying out water cooling on the power module and the DC capacitor.

Description

Technical Field

[0001] The utility model relates to the technical field of motor controllers, in particular to a motor controller for a single motor and its power components. Background Art

[0002] In a motor controller, the power component is the core component, and its volume, weight, and interface are the biggest obstacles to the miniaturization and platformization of the electric control. For example, a motor controller needs sensors to monitor the output current magnitude. In the prior art, current sensors of power components mostly adopt methods such as integration into the PCB and installation on the housing. The installation is complex, the requirements for the output interface position are high, and there are many parts, resulting in high costs. Another example is that in the prior art, capacitors exist independently and are assembled with the power unit through the housing. Usually, structures such as heat-conducting pads are also required. The structure is relatively complex, the volume is large, and the heat dissipation effect is not good. Summary of the Invention

[0003] In order to overcome the above technical defects, the purpose of the utility model is to provide a highly integrated power component for a motor controller for a single motor.

[0004] The utility model discloses a power component for a motor controller for a single motor, including: a capacitor housing, a DC capacitor is arranged in the capacitor housing; a power module is arranged on the top of the DC capacitor, the power module includes an AC current terminal and a signal terminal, and the AC current terminal and the signal terminal respectively extend out towards both sides of the capacitor housing; an AC transfer copper bar is arranged on the same side as the AC current terminal, and is used to connect the motor end AC copper bar of the motor and the AC current terminal of the power module; the AC transfer copper bar is detachably connected to the side surface of the capacitor housing through a copper bar plastic shell; a first cooling water channel is arranged on the upper surface of the power module, and is used to perform water cooling on the power module and the DC capacitor.

[0005] Preferably, it further includes a coreless current sensor, and the coreless current sensor is fixed on the copper bar plastic shell; the coreless current sensor includes at least two sampling chips, which respectively perform current sampling on at least two paths of the AC transfer copper bars.

[0006] Preferably, the coreless current sensor includes a PCBA motherboard and a PCBA daughter board. The PCBA motherboard is fixedly arranged on the copper bar plastic shell, the PCBA daughter board is vertically arranged and electrically connected to the PCBA motherboard, and a coreless current sensor chip is arranged on the PCBA daughter board; an opening is arranged on the AC transfer copper bar, and the PCBA daughter board vertically penetrates through the opening of the AC transfer copper bar to measure the current passing through the AC transfer copper bar.

[0007] Preferably, it further includes a PCBA drive board, which is arranged on the same side as the signal terminal of the power module and is electrically connected to the signal terminal of the power module for obtaining the signal output by the signal terminal.

[0008] Preferably, it further includes a DC transfer copper bar. One end of the DC transfer copper bar is connected to the DC current terminal of the power module, and the other end extends out from the side of the capacitor housing to connect to a DC current source; the DC transfer copper bar is arranged on the same side as the PCBA drive board.

[0009] Preferably, it further includes a second cooling water channel, which is arranged between the DC capacitor and the power module.

[0010] Preferably, end water channels are respectively arranged at both ends of the capacitor housing, and the end water channels are communicated with the second cooling water channel; a fluid inlet and a fluid outlet are arranged at the lower part of the capacitor housing, and the fluid inlet and the fluid outlet are respectively communicated with the two end water channels. Thus: cooling water enters one of the two end water channels through the fluid inlet, then flows through the first cooling water channel and the other end water channel, and finally flows out from the fluid outlet.

[0011] Preferably, the AC current terminal of the power module is bent towards the bottom surface of the capacitor housing to fit the side surface of the capacitor housing; the AC transfer copper bar is vertically bent, one end is electrically connected after fitting with the AC current terminal, and the other end extends away from the capacitor housing.

[0012] Preferably, an opening is arranged on one side of the capacitor housing, and the opening is potted with potting material to form a potted surface; the copper bar plastic shell is arranged on the potted surface.

[0013] The present invention also discloses a motor controller for a single motor, which includes the above-mentioned power component, and the power component is connected to the motor terminal AC copper bar through the AC transfer copper bar for controlling the motor.

[0014] After adopting the above technical solutions, compared with the prior art, it has the following beneficial effects:

[0015] 1. The present invention highly integrates the DC capacitor, the AC transfer copper bar, the first cooling water channel, the second cooling water channel, the non-magnetic core current sensor, the power module, and the PCBA drive board, which can reduce the volume of the power component, thereby realizing the high power density of the motor controller; the present invention flexibly sets the interface for cooperating with the motor, can adapt to a variety of different motor terminal interfaces, has strong platformization and low cost. Description of the Drawings

[0016] Figure 1 Explosion diagram of the power component of the motor controller provided by the present utility model;

[0017] Figure 2 Stereogram of the power component of the motor controller provided by the present utility model;

[0018] Figure 3 Stereogram of the power component of the motor controller provided by the present utility model from another perspective;

[0019] Figure 4 Stereogram of the power component of the motor controller provided by the present utility model showing the first cooling water channel;

[0020] Figure 5 Stereogram of the power component of the motor controller provided by the present utility model showing the first cooling water channel from another perspective.

[0021] Wherein: 1 - capacitor housing, 101 - potting surface, 2 - DC capacitor, 3 - power module, 301 - AC current terminal, 302 - signal terminal, 4 - AC transfer copper bar, 5 - copper bar plastic housing, 6 - first cooling water channel, 7 - second cooling water channel, 8 - non-magnetic core current sensor, 9 - PCBA drive board, 10 - DC transfer copper bar. Detailed implementation mode

[0022] The advantages of the present utility model are further elaborated below in conjunction with the accompanying drawings and specific embodiments.

[0023] Here, the exemplary embodiments will be described in detail, and the examples are shown in the accompanying drawings. When the following description refers to the accompanying drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with the present disclosure. On the contrary, they are merely examples of devices and methods consistent with some aspects of the present disclosure as detailed in the appended claims.

[0024] The terms used in the present disclosure are only for the purpose of describing specific embodiments and are not intended to limit the present disclosure. The singular forms "a", "the", and "said" used in the present disclosure and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term "and / or" used herein refers to and includes any and all possible combinations of one or more of the associated listed items.

[0025] It should be understood that although the terms first, second, third, etc. may be used in this disclosure to describe various information, such information should not be limited to these terms. These terms are only used to distinguish information of the same type from each other. For example, without departing from the scope of this disclosure, the first information may also be referred to as the second information, and similarly, the second information may also be referred to as the first information. Depending on the context, the word "if" as used herein may be interpreted as "when" or "while" or "in response to determining".

[0026] In the description of the present utility model, it should be understood that the orientation or positional relationship indicated by the terms "longitudinal", "transverse", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present utility model and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation to the present utility model.

[0027] In the description of the present utility model, unless otherwise specified and defined, it should be noted that the terms "installation", "connection", and "coupling" should be understood in a broad sense. For example, it may be a mechanical connection or an electrical connection, or it may be the communication inside two elements. It may be directly connected, or indirectly connected through an intermediate medium. For those of ordinary skill in the art, the specific meanings of the above terms can be understood according to specific circumstances.

[0028] In the subsequent description, the suffixes such as "module", "component", or "unit" used to represent elements are only for the convenience of describing the present utility model, and they do not have a specific meaning in themselves. Therefore, "module" and "component" can be used interchangeably.

[0029] See the attached Figures 1-3 , the present utility model discloses a power component for a motor controller of a single motor. For the power component, it generally includes a DC capacitor and a power module 3 (such as an IGBT module). A DC current is input to the power component, and after being processed by the DC capacitor and the power module 3, it flows out from the AC terminal of the power module 3. At this time, the output AC current needs to be output to the motor to achieve the control of the motor by the motor controller to which the power component belongs. Among them, the AC transfer busbar 4 is used to transfer the AC current output from the AC terminal of the power module 3 to the AC terminal of the motor.

[0030] The DC capacitor of the power component of the present utility model is arranged inside the capacitor housing 1, and the three-phase power module 3 is arranged on the top of the capacitor housing 1. The power module 3 includes an AC current terminal 301 and a signal terminal 302, and the AC current terminal 301 and the signal terminal 302 extend towards both sides of the capacitor housing 1 respectively. The AC adapter copper bar 4 is arranged on one side of the capacitor housing 1, specifically, it is arranged on the same side as the AC current terminal 301 of the power module 3, and is used to connect with the AC current terminal 301 of the power module 3 on the same side. One end of the AC adapter copper bar 4 is connected to the AC current terminal 301 of the power module 3, and the other end is connected to the motor terminal AC copper bar of the motor, so as to realize the connection between the motor terminal AC copper bar of the motor and the AC current terminal 301 of the power module 3, thereby outputting the output current of the motor controller to which the power component belongs to the motor, and realizing the control of the motor by the motor controller.

[0031] The AC adapter copper bar 4 is detachably connected to the side surface of the capacitor housing 1 through the copper bar plastic shell 5. It should be understood that the AC adapter copper bar 4 is carried by the copper bar plastic shell 5, and the copper bar plastic shell 5 is connected to the capacitor housing 1 (for example, by screw connection). After the DC capacitor is installed inside the capacitor housing 1, it is usually necessary to be potted with potting material, that is, sealed. There are usually two potting forms. One is to open the upper part of the capacitor housing 1 and perform potting on the upper part after installing the DC capacitor; the other is to open the side surface of the capacitor housing 1 and perform potting on the side surface after installing the DC capacitor. The present utility model opens the side surface of the capacitor housing 1 to place the capacitor and perform potting. And the copper bar plastic shell 5 is arranged on the potting surface 2 (for example, by screws), so that the AC adapter copper bar 4 is also arranged on the potting surface 2. The AC adapter copper bar 4 is connected to the AC current terminal 301 of the power module 3 and the motor terminal copper bar of the motor by laser welding.

[0032] Further preferably, the AC current terminal 301 of the power module 3 is bent towards the bottom surface of the capacitor housing 1 to fit the side surface of the capacitor housing 1; the AC adapter copper bar 4 is vertically bent into two parts. One part fits the capacitor housing 1 to be electrically connected after fitting with the AC current terminal 301, and the other part extends in a direction away from the capacitor housing 1 (vertically).

[0033] The present utility model also integrates a cooling water channel. The first cooling water channel 6 is arranged on the upper surface of the power module 3 and is used for water cooling of the power module 3 and the DC capacitor. Further, a second cooling water channel 7 is also provided. The second cooling water channel 7 is arranged between the DC capacitor and the power module 3. Specifically, it is on the top of the capacitor housing 1. Thus, the power module 3 dissipates heat on both sides through the upper and lower layers of cooling water channels, and at the same time, the secondary cooling water channel can also dissipate heat from the DC capacitor inside the capacitor housing 1.

[0034] An optional one, see the appendix Figures 4-5, both ends of the second cooling water channel 7 are connected to the first cooling water channel 6, thereby realizing the connection of the two-stage water channels and strengthening the circulation of the water channels. Further, the fluid inlet and the fluid outlet are arranged at the lower part of the capacitor housing 1, and the fluid inlet and the fluid outlet are connected to the second cooling water channel 7. Thus, the cooling water enters the second cooling water channel 7 through the fluid inlet (upward), then (upward again) flows through the first cooling water channel 6, (downward) flows through the second cooling water channel 7, and finally flows out from the fluid outlet.

[0035] Alternatively, end water channels (not shown in the figure) are respectively arranged at both ends of the capacitor housing 1, and the end water channels are connected to the second cooling water channel 7. It can be understood that the end water channels are part of the second cooling water channel 7. The fluid inlet and the fluid outlet are respectively connected to the two end water channels. Thus: the cooling water enters one of the two end water channels through the fluid inlet, then flows through the first cooling water channel 6 and the other end water channel, and finally flows out from the fluid outlet.

[0036] The utility model also integrates a coreless current sensor 8. The coreless current sensor 8 is arranged on one side of the capacitor housing 1 and is arranged on the same side as the AC transfer copper bar 4. Specifically, the coreless current sensor 8 is fixed to the copper bar plastic shell 5 by screws. The coreless current sensor 8 includes at least two sampling chips, which respectively sample the current of at least two AC transfer copper bars 4.

[0037] Further preferably, the coreless current sensor 8 includes a PCBA mother board and a PCBA daughter board. The PCBA mother board is fixedly arranged on the copper bar plastic shell 5. The PCBA daughter board is vertically arranged and electrically connected to the PCBA mother board. The coreless current sensor 8 chips are arranged on the PCBA daughter board. Openings are provided on the AC transfer copper bar 4, and the PCBA daughter board vertically penetrates through the openings of the AC transfer copper bar 4 to measure the current passing through the AC transfer copper bar 4.

[0038] The utility model also integrates a PCBA drive board 9. The PCBA drive board 9 is arranged on one side of the capacitor housing 1 and is arranged on the same side as the AC transfer copper bar 4. Specifically, the PCBA drive board 9 is arranged on the same side as the signal terminal 302 of the power module 3 and is electrically connected to the signal terminal 302 of the power module 3 to obtain the signal output by the signal terminal 302.

[0039] In summary, the utility model takes the capacitor housing 1 as the main body, horizontally assembles the cooling water channel and the power module 3 on the top of the capacitor. One of the two sides is used to fix the AC transfer copper row 4 and the non-magnetic core current sensor 8, and the other side is used to fix the PCBA drive board 9. The bottom of the capacitor housing 1 is provided with the water inlet and outlet of the cooling water channel (that is, the fluid inlet and fluid outlet). Thus, each component is tightly arranged around the capacitor housing 1, with a small space size. And the motor-side AC copper row used to cooperate with the power component of the utility model can be directly fixed to the AC transfer copper row 4 on the copper row plastic shell 5 by screws without additional transfer.

[0040] It should be noted that for a power brick structure (the power component described in the utility model), it generally includes a "power module 3 processing body" for the operation of the power module 3 (and its cooperation), and a "transfer component" for outputting the AC current output by the "power module 3 processing body" to the motor. The above-mentioned copper row plastic shell 5 and the AC transfer copper row 4 thereon of the utility model belong to the "transfer component", and the other components integrated on the capacitor housing 1 are the "power module 3 processing body". Generally, the "transfer component" needs to be designed differently according to the structure of the motor to cooperate with the AC three-phase input of the motor. Due to the transfer part in the prior art, it is usually difficult to clearly divide the "transfer component" from the "power module 3 processing body". The utility model can achieve this, so that the "power module 3 processing body" is used as a general component, and the "transfer component" is used as a replaceable component. Facing different motors, only the structure of the "transfer component" (the copper row plastic shell 5 and the AC transfer copper row 4 thereon) needs to be redesigned, without the need to make corresponding structural adjustments to the "power module 3 processing body".

[0041] Furthermore, a DC transfer copper row 10 is also integrated. The DC transfer copper row 10 is arranged on the same side as the PCBA drive board 9. Specifically, one end of the DC transfer copper row 10 is connected to the DC current terminal of the power module 3, and the other end extends out from the side of the capacitor housing 1 to connect to the DC current source. There is a vacancy at the edge of the PCBA drive board 9, which is used to accommodate the DC transfer copper row 10.

[0042] It includes the above-mentioned power component. The motor controller is connected to the motor for controlling the motor. Specifically, the "power module 3 processing body" is connected to the motor through the "transfer component", so that the AC transfer copper row 4 of the motor in the "transfer component" outputs the AC current processed by the power module 3 in the "power module 3 processing body" to the motor-side AC copper row of the motor, thereby realizing the control of the motor.

[0043] It should be noted that the embodiments of the present utility model have better implementability and do not impose any form of limitation on the present utility model. Any person skilled in the art may use the disclosed technical content to modify or transform it into equivalent effective embodiments. However, as long as the content does not depart from the technical solution of the present utility model, any modification, equivalent change or modification made to the above embodiments based on the technical essence of the present utility model still falls within the scope of the technical solution of the present utility model.

Claims

1. A power assembly for a motor controller of a single motor, characterized in that: include: A capacitor housing, in which a DC capacitor is disposed; A power module is arranged on the top of the DC capacitor, the power module comprises an AC current terminal and a signal terminal, the AC current terminal and the signal terminal extend toward two sides of the capacitor housing respectively; An AC transfer copper busbar, arranged on the same side as the AC current terminal, for connecting the motor-end AC copper busbar of the motor and the AC current terminal of the power module; The AC transfer copper bar is detachably connected to the side of the capacitor housing through the copper bar plastic shell; The first cooling water channel is arranged on the upper surface of the power module and is used for water cooling the power module and the DC capacitor.

2. The power assembly of the motor controller for a single motor according to claim 1, characterized in that: It also includes a coreless current sensor, which is fixed on the copper busbar plastic shell; The coreless current sensor comprises at least two sampling chips, which respectively perform current sampling on at least two AC switching copper bars.

3. The power assembly of the motor controller for a single motor according to claim 2, characterized in that: The coreless current sensor comprises a PCBA motherboard and a PCBA daughterboard, wherein the PCBA motherboard is fixedly arranged on the copper busbar plastic shell, the PCBA daughterboard is vertically arranged and electrically connected to the PCBA motherboard, and a coreless current sensor chip is arranged on the PCBA daughterboard; The AC transfer copper busbar is provided with an opening, and the PCBA sub-board is vertically inserted into the opening of the AC transfer copper busbar to measure the current passing through the AC transfer copper busbar.

4. The power assembly of the motor controller for a single motor according to claim 1, characterized in that: It also includes a PCBA driver board, which is arranged on the same side as the signal terminal of the power module and is electrically connected to the signal terminal of the power module for acquiring the signal output by the signal terminal.

5. The power assembly of the motor controller for a single motor according to claim 4, characterized in that: It also includes a DC transfer copper bar, one end of which is connected to the DC current terminal of the power module, and the other end of which extends from the side of the capacitor housing to be connected to a DC current source; The DC transfer copper bar is arranged on the same side as the PCBA driver board.

6. The power assembly of the motor controller for a single motor according to claim 1, characterized in that: It also includes a second cooling water channel, which is arranged between the DC capacitor and the power module.

7. The power assembly of the motor controller for a single motor according to claim 6, characterized in that: The capacitor housing is provided with end water channels at both ends, and the end water channels are connected with the second cooling water channel; The fluid inlet and the fluid outlet are arranged at the lower part of the capacitor housing, and the fluid inlet and the fluid outlet are respectively connected to the two end water channels, whereby: the cooling water enters one of the two end water channels through the fluid inlet, then flows through the first cooling water channel, the other end water channel, and finally flows out from the fluid outlet.

8. The power assembly of the motor controller for a single motor according to claim 1, characterized in that: The AC current terminal of the power module is bent toward the bottom surface of the capacitor housing to fit the side surface of the capacitor housing; The AC transfer copper bar is vertically bent, one end of which is electrically connected to the AC current terminal after being attached thereto, and the other end of which extends in a direction away from the capacitor housing.

9. The power assembly of the motor controller for a single motor according to claim 1, characterized in that: An opening is provided on one side of the capacitor housing, and the opening is potted with a potting material to form a potting surface; The copper busbar plastic shell is arranged on the potting surface.

10. A motor controller for a single motor, characterized in that: It comprises the power component described in any one of claims 1 to 9 above, wherein the power component is connected to the AC copper bus at the motor end through the AC transfer copper bus, so as to control the motor.

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