All-in-one power domain motor controller for new energy automobile

Abstract

The utility model discloses an all-in-one power domain motor controller for a new energy automobile, particularly relates to the field of motor controllers, and comprises a box body and cover plates arranged on the upper side and the lower side of the box body, and a first low-voltage signal connector, a second low-voltage signal connector and a third low-voltage signal connector are arranged between the box body and the top cover plate. According to the utility model, the first low-voltage signal connector, the second low-voltage signal connector and the third low-voltage signal connector which are arranged can communicate with CAN buses of other vehicle-mounted systems and are used for monitoring the state of a motor, and the slow charging connector, the quick charging connector, the PDU output connector, the high-voltage input connector and the DCDC connector are integrated on the periphery of the box body. Wiring can be simplified, wiring among a plurality of independent modules is reduced, the failure rate is reduced, the total size and weight are reduced, only one device needs to be concerned during maintenance, the maintenance cost and complexity are reduced, the installation process is simplified, and the operation efficiency of the motor is improved.

Description

Technical Field

[0001] The utility model relates to the technical field of motor controllers, and more specifically, to a multi-in-one power domain motor controller for new energy vehicles. Background Art

[0002] The motor controller of new energy vehicles is one of the core components in new energy vehicles such as electric vehicles (EV) and hybrid electric vehicles (HEV). It is responsible for controlling the operating state of the drive motor to achieve functions such as the driving and stopping of the vehicle. The role of the motor controller is crucial, directly affecting the performance, efficiency, and safety of the vehicle. By controlling the speed, torque, and direction of the motor, functions such as vehicle acceleration, deceleration, and steering are realized;

[0003] At present, the motor controller of new energy vehicles has a single function, is connected to many external devices, requires multiple wire harnesses and connectors for connection, and multiple devices occupy a large installation space, increasing the overall volume and weight. Moreover, when maintaining, multiple devices need to be concerned about, increasing the maintenance cost and complexity, resulting in a relatively complex installation process, which easily affects the reliable operation of the motor controller. Therefore, a multi-in-one power domain motor controller for new energy vehicles is proposed. Summary of the Utility Model

[0004] In order to overcome the above-mentioned defects of the prior art, the utility model provides a multi-in-one power domain motor controller for new energy vehicles to solve the problems mentioned in the above background art.

[0005] To achieve the above purpose, the utility model provides the following technical solution: A multi-in-one power domain motor controller for new energy vehicles includes a box body and cover plates arranged on the upper and lower sides of the box body. Between the box body and the top cover plate, there are a first low-voltage signal connector, a second low-voltage signal connector, and a third low-voltage signal connector. In the middle of one end of the box body near the first low-voltage signal connector, there are a water inlet pipe, a water outlet pipe, and a fuse installation cover plate;

[0006] In the middle of one side of the box body near the third low-voltage signal connector, there are a slow charging connector and a fast charging connector. In the middle of the other side of the box body far from the third low-voltage signal connector, there are a PDU output connector and a breather valve. On the other side of the box body far from the first low-voltage signal connector, there are a high-voltage input connector and a DCDC connector;

[0007] At the bottom of the bottom cover plate, there are two groups of motor input copper bars, and installation feet are fixedly connected to the periphery of the bottom cover plate.

[0008] Preferably, the first low-voltage signal connector, the second low-voltage signal connector, and the third low-voltage signal connector are used to connect to the CAN bus of other vehicle-mounted systems.

[0009] Preferably, the inlet pipe and the outlet pipe are used to convey coolant. A cooling channel connected to the inlet pipe and the outlet pipe is provided in the middle of the box body, and the inlet pipe and the outlet pipe are connected to the inlet and outlet pipes of an external radiator.

[0010] Preferably, the fuse mounting cover plate is used in connection and cooperation with the PDU interface wiring harness, and a fuse is provided in the middle of the mounting cover plate.

[0011] Preferably, the slow charging connector is used to provide a slower charging speed, the fast charging connector is used to rapidly charge the battery pack, and the PDU output connector is used to connect with the wires of the auxiliary system in the vehicle.

[0012] Preferably, the breather valve is made of a waterproof and breathable material and is used to keep the pressure inside the box body consistent with the external pressure. The high-voltage input connector is used to be electrically connected to the motor controller.

[0013] Preferably, the DCDC connector is used to draw out a high-voltage DC power supply to supply power to high-power vehicle-mounted electrical appliances, the motor input copper bar is used to supply power to the motor, and the mounting feet are used to connect and fix to the motor power assembly end.

[0014] The technical effects and advantages of the present utility model:

[0015] 1. Firstly, by providing the first low-voltage signal connector, the second low-voltage signal connector, and the third low-voltage signal connector, the present utility model can communicate with the CAN bus of other vehicle-mounted systems, receive signals from sensors such as temperature sensors and position sensors, be used to monitor the motor state, and integrate the slow charging connector, the fast charging connector, the PDU output connector, the high-voltage input connector, and the DCDC connector around a box body, which can simplify the wiring, reduce the wiring between multiple independent modules, reduce the failure rate, and reduce the overall volume and weight. At the same time, during maintenance, only one device needs to be concerned about, reducing the maintenance cost and complexity, simplifying the installation process, and improving the operating efficiency of the motor;

[0016] 2. The present utility model also can input coolant into the cooling channel of the box body through the provided inlet pipe and outlet pipe, take away the heat inside the box body, play a role in cooling, ensure that the motor controller works within an efficient and safe temperature range, conveniently match and install the box body with the motor power assembly end through the mounting feet, complete a highly integrated power assembly, meet the requirements of vehicle development. At the same time, through the provided breather valve, gas is allowed to pass through but liquid and dust are prevented from entering, which conveniently keeps the pressure inside the box body the same as the outside, avoids the box body from deforming or being damaged due to overpressure, and improves the use effect.

[0017] In summary, through the mutual influence of the above multiple functions, the wiring can be simplified, the wiring between multiple independent modules is reduced, the failure rate is lowered, and the overall volume and weight are reduced. At the same time, only one device needs to be concerned about during maintenance, reducing the maintenance cost and complexity, simplifying the installation process, improving the operating efficiency of the motor, and facilitating heat dissipation and installation and use. Brief Description of the Drawings

[0018] Figure 1 It is a schematic diagram of the overall structure of the present utility model.

[0019] Figure 2 It is a schematic diagram of the structure of the present utility model from another angle.

[0020] Figure 3 It is a front view schematic diagram of the present utility model.

[0021] Figure 4 It is a side view schematic diagram of the present utility model.

[0022] The reference numerals are: 1, box body; 2, cover plate; 3, first low-voltage signal connector; 4, second low-voltage signal connector; 5, third low-voltage signal connector; 6, water inlet pipe; 7, water outlet pipe; 8, fuse installation cover plate; 9, slow charging connector; 10, fast charging connector; 11, PDU output connector; 12, breather valve; 13, high-voltage input connector; 14, DCDC connector; 15, motor input copper bar; 16, mounting foot. Detailed Embodiments

[0023] Next, the technical solutions in the embodiments of the present utility model will be clearly and completely described in conjunction with the drawings in the embodiments of the present utility model. Obviously, the described embodiments are only a part of the embodiments of the present utility model, rather than all the embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present utility model.

[0024] As shown in the attached Figures 1-4An integrated motor controller for a new energy vehicle power domain is shown, which includes a box body 1 and cover plates 2 arranged on the upper and lower sides of the box body 1. A first low-voltage signal connector 3, a second low-voltage signal connector 4, and a third low-voltage signal connector 5 are arranged between the box body 1 and the top cover plate 2. Through the first low-voltage signal connector 3, the second low-voltage signal connector 4, and the third low-voltage signal connector 5, it can communicate with the CAN bus of other vehicle-mounted systems, receive signals from sensors such as temperature sensors and position sensors for monitoring the motor status, and receive control instructions from the vehicle electronic control unit, such as acceleration and deceleration. In the middle of one end of the box body 1 close to the first low-voltage signal connector 3, a water inlet pipe 6, a water outlet pipe 7, and a fuse installation cover plate 8 are arranged. The coolant flows out from the radiator, is pressurized by the water pump, and then is transported to the cooling channel of the motor controller through the pipeline. The coolant absorbs heat inside the motor controller and the temperature rises. The heated coolant returns to the radiator water cooling system through the pipeline to take away heat through liquid circulation, ensuring that the motor controller works within an efficient and safe temperature range. This system consists of a coolant, a radiator, a water pump, pipelines, temperature sensors, a control unit, etc., all of which are prior arts and the specific structures are not limited. It has the advantages of efficient heat dissipation, low noise, high reliability, etc., and is used in cooperation with the PDU interface wire harness through the fuse installation cover plate 8 to protect the circuit when the electrical appliance module is overloaded. After the fuse melts, it is convenient to disassemble and replace;

[0025] On the middle part of one side of the box body 1 close to the third low-voltage signal connector 5, there are a slow charging connector 9 and a fast charging connector 10. The slow charging connector 9 provides a slower charging speed for the vehicle, which has the advantages of high safety, low cost, and popularization of charging infrastructure. Through the fast charging connector 10, a fast charging function is integrated. The battery pack is charged with direct current DC through the high-voltage connector, with a high charging power and a fast charging speed. It is on the same side as the fuse mounting cover plate 8, which is convenient for the vehicle assembly to plug and unplug. On the middle part of the side of the box body 1 far from the third low-voltage signal connector 5, there are a PDU output connector 11 and a breather valve 12. Through the provided breather valve 12, gas is allowed to pass through while preventing liquid and dust from entering, avoiding short-circuit failure of the equipment. When the pressure inside the box body 1 is higher than the external environmental pressure, the breather valve 12 can release the excess gas or steam to prevent the box body 1 from deforming or being damaged due to overpressure. When the pressure inside the box body 1 is lower than the external environmental pressure, the breather valve 12 allows external air to enter the box body 1 to prevent the box body 1 from collapsing due to negative pressure or inhaling external pollutants. Through the PDU output connector 11, a high-voltage DC power supply can be led out to supply power to other modules. And the PDU output connector 11 is connected by an internal structure wire harness design to continuously output a stable high-voltage current to supply power to in-vehicle high-power electrical appliances. On the side of the box body 1 far from the first low-voltage signal connector 3, there are a high-voltage input connector 13 and a DCDC connector 14. Through the high-voltage input connector 13 combined with the high-voltage connector, the direct current in the battery pack is introduced into the motor controller. Different functional outputs are provided through different modules. The DCDC module is integrated into the overall design through the DCDC connector 14 to convert the voltage of the high-voltage battery pack into a low voltage such as 12V or 24V for use by the auxiliary system in the vehicle, providing a stable power supply for the vehicle's low-voltage electrical equipment and being able to work stably and continuously in the range of -40°C to 105°C. Whether in low-temperature working conditions or high-temperature harsh environments, the DCDC dissipates heat through internal structure liquid cooling and achieves a good heat dissipation effect under a unique thermal design;

[0026] On the bottom of the bottom cover plate 2, there are two groups of motor input copper bars 15. The four sides of the bottom cover plate 2 are fixedly connected with mounting feet 16. The high-voltage direct current is converted into three-phase alternating current through the motor input copper bars 15 by the internal IGBT module to continuously supply current to the motor. Through the mounting feet 16, it can be matched and installed with the motor power assembly end to complete a highly integrated power assembly and meet the vehicle development requirements.

[0027] As shown in the Figure 1 attachment, the first low-voltage signal connector 3, the second low-voltage signal connector 4, and the third low-voltage signal connector 5 are used to connect to the CAN bus of other vehicle-mounted systems, receive signals from sensors such as temperature sensors and position sensors, and are used to monitor the motor state and receive control instructions from the vehicle electronic control unit, such as acceleration and deceleration.

[0028] As shown in the attached Figure 1 and 3 shown, the inlet pipe 6 and the outlet pipe 7 are used to convey the coolant. A cooling channel connected to the inlet pipe 6 and the outlet pipe 7 is provided in the middle of the box body 1. The inlet pipe 6 and the outlet pipe 7 are connected to the inlet and outlet pipes of an external radiator. After the coolant flows out of the radiator and is pressurized by a water pump, it is conveyed into the cooling channel of the box body 1. The coolant absorbs heat inside the box body 1 and its temperature rises. The heated coolant returns to the radiator water cooling system through a pipeline, and the heat is carried away through liquid circulation to ensure that the box body 1 operates within an efficient and safe temperature range.

[0029] As shown in the attached Figure 1 and 3 shown, the fuse installation cover plate 8 is used for connection and cooperation with the PDU interface wiring harness. A fuse is provided in the middle of the installation cover plate 8 to protect the circuit when the electrical appliance module is overloaded. After the fuse melts, it is convenient to disassemble and replace.

[0030] As shown in the attached Figure 1 and 4 shown, the slow charging connector 9 is used to provide a slower charging speed and has advantages such as high safety, low cost, and popularization of charging infrastructure. The fast charging connector 10 is used to quickly charge the battery pack. The PDU output connector 11 is used to connect with the wires of the auxiliary system in the vehicle. Through the fast charging connector 10, the fast charging function is integrated and designed. The battery pack is charged with direct current DC through a high-voltage connector, with a high charging power and a fast charging speed. It is on the same side as the fuse installation cover plate 8, which is convenient for the whole vehicle assembly to plug and unplug. Through the PDU output connector 11, a stable high-voltage current is continuously output to supply power to high-power in-vehicle electrical appliances.

[0031] As shown in the attached Figure 2 and 4 shown, the breather valve 12 is made of a waterproof and breathable material and is used to keep the pressure inside the box body consistent with the external pressure. The high-voltage input connector 13 is used to electrically connect with the motor controller. The breather valve 12 allows gas to pass through but prevents liquid and dust from entering, avoiding short-circuit failure of the equipment. Through the high-voltage input connector 13 combined with the high-voltage connector, the direct current in the battery pack is introduced into the motor controller, and different functional outputs are provided through different modules.

[0032] As shown in the attached Figure 1 and 2, as shown in Figure 4, the DCDC connector 14 is used to draw out the high-voltage DC power supply to supply power to high-power in-vehicle electrical appliances, the motor input copper busbar 15 is used to supply power to the motor, and the mounting feet 16 are used to connect and fix to the motor power assembly end. The DCDC module is integrated into the overall design through the DCDC connector 14, converting the voltage of the high-voltage battery pack into a low voltage such as 12V or 24V for use in the auxiliary system of the vehicle, providing a stable power supply for the low-voltage electrical equipment of the vehicle. The high-voltage direct current is converted into three-phase alternating current through the internal IGBT module by the motor input copper busbar 15 to continuously supply current to the motor. The mounting feet 16 can be matched and installed with the motor power assembly end to complete the highly integrated power assembly and meet the requirements of the vehicle development;

[0033] It should be noted that the box body 1 is a multi-in-one controller box body. The internal space utilization rate of the box body 1 is high, with multiple functional modules and structural components integrated inside, and multiple connector installation interfaces integrated outside to achieve input or output to the outside and inside. At the same time, the box body is sealed with the cover plate 2 on the upper and lower sides, both of which are made of die-cast aluminum alloy, with light weight and high material strength, meeting the requirements of vehicle-grade vibration and protection level.

[0034] The working principle of the present utility model: When in use, it can communicate with the CAN bus of other vehicle-mounted systems through the first low-voltage signal connector 3, the second low-voltage signal connector 4, and the third low-voltage signal connector 5, receiving signals from sensors such as temperature sensors and position sensors for monitoring the motor status. The fuse mounting cover plate 8 is used in cooperation with the PDU interface wire harness to protect the circuit when the electrical appliance module is overloaded. After the fuse melts, it is convenient to disassemble and replace. The slow charging connector 9 provides a slower charging speed for the vehicle. The fast charging connector 10 integrates the fast charging function design, and the battery pack is charged with direct current DC through the high-voltage connector. Through the provided breather valve 12, gas is allowed to pass through while preventing liquid and dust from entering, facilitating the maintenance of the same pressure inside and outside the box body 1 and avoiding deformation or damage of the box body 1 due to overpressure;

[0035] Through the PDU output connector 11, the high-voltage DC power supply can be drawn out to supply power to other modules. The direct current in the battery pack is introduced into the motor controller through the high-voltage input connector 13 combined with the high-voltage connector. Different functional outputs are provided through different modules. The DCDC module is integrated into the overall design through the DCDC connector 14, converting the voltage of the high-voltage battery pack into a low voltage such as 12V or 24V for use in the auxiliary system of the vehicle, providing a stable power supply for the low-voltage electrical equipment of the vehicle;

[0036] When cooling the inside of the box body 1, the coolant flows out from the external radiator, is pressurized by the water pump and conveyed through the water inlet pipe 6 into the cooling channel of the box body 1. The coolant absorbs heat and its temperature rises, and then returns to the radiator water cooling system through the water outlet pipe 7 to take away the heat, ensuring that the motor controller works within the efficient and safe temperature range.

[0037] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. An all-in-one power domain motor controller for new energy vehicles, characterized by: The invention comprises a box body (1) and cover plates (2) arranged on the upper and lower sides of the box body (1); a first low-voltage signal connector (3), a second low-voltage signal connector (4), and a third low-voltage signal connector (5) are arranged between the box body (1) and the top cover plate (2); and a water inlet pipe (6), a water outlet pipe (7), and a fuse installation cover plate (8) are arranged in the middle of one end of the box body (1) close to the first low-voltage signal connector (3); A slow-charge connector (9) and a fast-charge connector (10) are arranged in the middle of a side of the box (1) close to the third low-voltage signal connector (5); a PDU output connector (11) and a vent valve (12) are arranged in the middle of a side of the box (1) away from the third low-voltage signal connector (5); and a high-voltage input connector (13) and a DCDC connector (14) are arranged on a side of the box (1) away from the first low-voltage signal connector (3); Two groups of motor input copper bars (15) are arranged at the bottom of the bottom cover plate (2), and mounting feet (16) are fixedly connected around the four sides of the bottom cover plate (2).

2. The all-in-one power domain motor controller for new energy vehicles according to claim 1 is characterized in that: The first low-voltage signal connector (3), the second low-voltage signal connector (4), and the third low-voltage signal connector (5) are used to connect to the CAN bus of other vehicle-mounted systems.

3. The all-in-one power domain motor controller for new energy vehicles according to claim 1 is characterized in that: The water inlet pipe (6) and the water outlet pipe (7) are used to transport cooling liquid. A cooling channel connected to the water inlet pipe (6) and the water outlet pipe (7) is provided in the middle of the box body (1). The water inlet pipe (6) and the water outlet pipe (7) are connected to the water inlet and outlet pipes of an external radiator.

4. The all-in-one power domain motor controller for new energy vehicles according to claim 1 is characterized in that: The fuse installation cover plate (8) is used for connection with a PDU interface harness, and a fuse is arranged in the middle of the installation cover plate (8).

5. The all-in-one power domain motor controller for new energy vehicles according to claim 1 is characterized in that: The slow charging connector (9) is used to provide a slower charging speed, the fast charging connector (10) is used to quickly charge the battery pack, and the PDU output connector (11) is used to connect to auxiliary system wires in the vehicle.

6. The all-in-one power domain motor controller for new energy vehicles according to claim 1, characterized in that: The air valve (12) is made of waterproof and breathable material and is used to keep the internal pressure of the box consistent with the external pressure. The high-voltage input connector (13) is used to be electrically connected to the motor controller.

7. The all-in-one power domain motor controller for new energy vehicles according to claim 1, characterized in that: The DCDC connector (14) is used to lead out a high-voltage direct current power supply to supply power to high-power electrical appliances on board the vehicle, the motor input copper busbar (15) is used to supply power to the motor, and the mounting foot (16) is used to be connected and fixed to the motor powertrain end.

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