Relay assembly, motor controller, power assembly and vehicle

Abstract

The utility model relates to a relay assembly, a motor controller, a power assembly and a vehicle. The relay assembly comprises a shell-less relay; the relay mounting seat is provided with an accommodating cavity for accommodating the shell-less relay; and at least a main body part of the copper bar is arranged along the side wall of the accommodating cavity, and the copper bar is electrically connected with the shell-less relay. The shell-less relay is smaller in outer contour size and free of structures such as installation feet, the overall occupied space of the relay is reduced, and arrangement and installation of the shell-less relay are facilitated. At least the main body part of the copper bar is arranged on the side wall of the accommodating cavity, so that the overall integration level of the relay assembly is improved. The copper bars are arranged on the side wall of the accommodating cavity, so that the copper bars can be closer to the shell-less relay, compared with the mode that the copper bars are arranged on the outer side of the relay mounting seat at intervals, the length of the required copper bars can be effectively reduced, and electric connection between the copper bars and the shell-less relay can be more conveniently and directly formed (an electric connection structure does not need to be arranged); the relay assembly structure is simplified, and the cost and the occupied space are reduced.

Description

Technical Field

[0001] The present disclosure relates to the technical field of motor controllers, and more particularly, to a relay assembly, a motor controller, a power assembly, and a vehicle. Background Art

[0002] A relay is an important component in a motor controller, which plays roles such as switch control, circuit isolation, and overload protection. In related technologies, a relay includes a housing and electrical components disposed inside the housing. The housing of the relay is provided with mounting feet, and the relay can be mounted on the box body of the motor controller through the mounting feet. In order to form an electrical connection between the relay and other components of the motor controller, the motor controller further includes a plurality of busbars for electrically connecting to the relay, and the busbars are arranged around the relay. However, the relay housing and the mounting feet occupy a large space, which is not conducive to the utilization of the internal space of the motor controller, and also results in an increase in the usage amount (such as length) of the required busbars. Summary of the Utility Model

[0003] The purpose of the present disclosure is to provide a relay assembly, a motor controller, a power assembly, and a vehicle to at least partially solve the problems existing in related technologies.

[0004] To achieve the above purpose, the present disclosure provides a relay assembly, including: a shell-less relay; a relay mounting seat having a receiving cavity for receiving the shell-less relay; and a busbar, at least a main part of which is arranged along the side wall of the receiving cavity, and the busbar is electrically connected to the shell-less relay.

[0005] Optionally, at least a main part of the busbar is embedded in the side wall of the relay mounting seat.

[0006] Optionally, the shell-less relay includes a positive relay and a negative relay, and the receiving cavity includes a first receiving cavity for receiving the positive relay and a second receiving cavity for receiving the negative relay.

[0007] Optionally, the positive relay has a first terminal and a second terminal, the negative relay has a third terminal and a fourth terminal, and the busbar includes: a first DC charging positive busbar, one end of which is electrically connected to the first terminal and the other end is for electrically connecting to a DC charging bus; a second DC charging positive busbar, one end of which is electrically connected to the second terminal and the other end is for electrically connecting to a capacitor; a first DC charging negative busbar, one end of which is electrically connected to the third terminal and the other end is for electrically connecting to the DC charging bus; and a second DC charging negative busbar, one end of which is electrically connected to the fourth terminal and the other end is for electrically connecting to the capacitor.

[0008] Optionally, the positive relay is mechanically connected to the first DC charging positive copper busbar and the second DC charging positive copper busbar through the first terminal and the second terminal; the negative relay is mechanically connected to the first DC charging negative copper busbar and the second DC charging negative copper busbar through the third terminal and the fourth terminal.

[0009] Optionally, the positive relay and the negative relay are respectively cemented to the relay mounting seat.

[0010] Optionally, it further includes: a first adapter copper busbar, one end of which is electrically connected to the end of the second DC charging positive copper busbar away from the second terminal, and the other end is used for electrically connecting the capacitor; and a second adapter copper busbar, one end of which is electrically connected to the end of the second DC charging negative copper busbar away from the fourth terminal, and the other end is used for electrically connecting the capacitor.

[0011] Optionally, the size of the positive relay in the height direction is greater than its size in the width direction and length direction; the size of the negative relay in the height direction is greater than its size in the width direction and length direction.

[0012] Optionally, it further includes a first adapter board for electrically connecting to the main control board, wherein the copper busbar is formed with a plurality of first conductive members for electrically connecting to the first adapter board, and / or the shell-less relay is formed with a second conductive member for electrically connecting to the first adapter board.

[0013] Optionally, it further includes a magnetic ring installed on the relay mounting seat, and the magnetic ring is used for the DC charging busbar to pass through.

[0014] According to the second aspect of the present disclosure, there is provided a motor controller, including a box body, a main control board accommodated in the box body, a capacitor accommodated in the box body, and the above-mentioned relay assembly.

[0015] Optionally, it further includes a silicon steel sheet for concentrating the magnetic field of the copper busbar and a Hall chip for sensing the magnetic field, and the Hall chip is electrically connected to the main control board, wherein the silicon steel sheet and the Hall chip are separately arranged.

[0016] Optionally, the motor controller further includes a driver, wherein the Hall chip is integrated on the upper surface of the driver; or the Hall chip is integrated on the lower surface of the driver; or the motor controller further includes a second adapter board arranged on the lower side of the driver, and the Hall chip is integrated on the second adapter board.

[0017] Optionally, it further includes a fuse element, and the fuse element is integrated on the capacitor.

[0018] Optionally, the box body is provided with a water inlet pipe and a water outlet pipe. The water inlet pipe is used to connect to a cooling water source, and the water outlet pipe is used to connect to the water inlet of the motor. Among them, at least one of the water inlet pipe and the water outlet pipe is integrally formed with the box body.

[0019] Optionally, at least a part of the box body is used to extend downward between the motor and the reducer.

[0020] Optionally, fastening holes are respectively provided on the end faces of the part of the box body extending between the motor and the reducer facing the motor and the reducer for respectively fastening connections with the motor and the reducer.

[0021] Optionally, the box body is provided with a first opening for installing a three-phase magnetic ring fixing seat and a second opening for installing a resolver wire harness. Among them, a first sealing ring is provided between the three-phase magnetic ring fixing seat and the box body, and a second sealing ring is provided between the resolver wire harness and the box body.

[0022] According to a second aspect of the present disclosure, a powertrain is provided, including a motor, a reducer, and the above-mentioned motor controller.

[0023] According to a third aspect of the present disclosure, a vehicle is provided, including the above-mentioned powertrain.

[0024] Through the above technical solutions, by using a shell-less relay and installing it in the accommodation cavity of the relay mounting seat, the integration degree of the relay assembly can be improved. And since the shell-less relay has a smaller outer contour size compared with the traditional shelled relay and has no structures such as mounting feet, the overall occupied space of the relay is reduced, which is beneficial to its layout and installation. In addition, at least the main part of the copper bar is arranged on the side wall of the accommodation cavity, further improving the overall integration degree of the relay assembly. And by installing the copper bar on the side wall of the accommodation cavity, it can be closer to the shell-less relay. Compared with arranging the copper bar at intervals outside the relay mounting seat, it can effectively reduce the required length of the copper bar and more conveniently form a direct electrical connection between the copper bar and the shell-less relay (without setting an electrical connection structure therebetween), simplifying the structure of the relay assembly, reducing costs and occupied space.

[0025] Other features and advantages of the present disclosure will be described in detail in the subsequent specific implementation part. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The drawings are used to provide a further understanding of the present disclosure, and constitute a part of the specification. Together with the following specific implementation, they are used to explain the present disclosure, but do not constitute a limitation to the present disclosure. In the drawings:

[0027] Figure 1 is an exploded view of a relay assembly exemplarily shown according to the present disclosure;

[0028] Figure 2 is Figure 1 A further exploded view of the relay assembly shown in [[ID=]], in which the first transfer copper bar and the second transfer copper bar are omitted;

[0029] Figure 3 is an exploded view of another relay assembly exemplarily shown according to the present disclosure;

[0030] Figure 4 is an exploded view of a motor controller exemplarily shown according to the present disclosure;

[0031] Figure 5 is Figure 4 a top view of the motor controller shown in [[ID=]];

[0032] Figure 6 is Figure 4 a front view cross-sectional view of the motor controller shown in [[ID=]];

[0033] Figure 7 is Figure 4 a partial cross-sectional view of the motor controller shown in [[ID=]], in which the cooperation relationship between the three-phase magnetic ring fixing seat and the resolver harness and the box body is shown;

[0034] Figure 8 is a schematic diagram of the distribution of Hall chips and silicon steel sheets in a motor controller exemplarily shown according to the present disclosure;

[0035] Figure 9 is a schematic diagram of the distribution of Hall chips and silicon steel sheets in another motor controller exemplarily shown according to the present disclosure;

[0036] Figure 10 is a schematic diagram of the distribution of Hall chips and silicon steel sheets in another motor controller exemplarily shown according to the present disclosure.

[0037] Description of Reference Numerals

[0038] 100 - Relay mounting base; 110 - First receiving cavity; 120 - Second receiving cavity; 210 - Positive relay; 211 - First terminal; 212 - Second terminal; 220 - Negative relay; 221 - Third terminal; 222 - Fourth terminal; 310 - First DC charging positive copper bar; 320 - Second DC charging positive copper bar; 330 - First DC charging negative copper bar; 340 - Second DC charging negative copper bar; 350 - First adapter copper bar; 360 - Second adapter copper bar; 401 - DC charging busbar; 402 - Capacitor; 403 - Main control board; 404 - Magnetic ring; 405 - Box body; 406 - Box cover; 407 - Silicon steel sheet; 408 - Hall chip; 409 - Driver; 410 - Second adapter board; 411 - Fuse element; 412 - Three - phase magnetic ring fixing seat; 413 - Resolver harness; 500 - First adapter board; 601 - First conductive part; 602 - Second conductive part; 610 - Water inlet pipe; 620 - Water outlet pipe; 700 - Motor; 800 - Reducer; 910 - Fastening hole; 920 - First sealing ring; 930 - Second sealing ring. Detailed implementation manners

[0039] The following will describe the detailed implementation manners of the present disclosure with reference to the accompanying drawings. It should be understood that the detailed implementation manners described herein are only used to illustrate and explain the present disclosure, and are not used to limit the present disclosure.

[0040] In the present disclosure, unless otherwise stated, based on the context, the orientation terms such as "inside, outside", "upper, lower" can be based on the structure of the relevant components themselves, or can be based on the orientation when the relevant components are used in cooperation. For example, at least the main part of the copper bar is embedded "inside" the side wall of the relay mounting base, which means that at least part of the copper bar is embedded inside the side wall in the thickness direction; the Hall chip is integrated on the "upper" surface of the driver; or the Hall chip is integrated on the "lower" surface of the driver. Here, "upper, lower" are based on the "upper, lower" of the motor controller. Specifically, the "upper" surface refers to the end of the driver away from the bottom of the box body of the motor controller, and the "lower" surface refers to the end of the driver facing the bottom of the box body of the motor controller. When the motor controller is installed on the vehicle, its "upper, lower" refers to the upper and lower in the vehicle body height direction.

[0041] In the present disclosure, the terms "first", "second", etc. are used to distinguish one element from another element, and do not have sequentiality and importance. When the following description refers to the accompanying drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements.

[0042] Refer to Figures 1 - 3, the present disclosure exemplarily shows a relay assembly, including a shell-less relay, a relay mounting base 100 having a receiving cavity for receiving the shell-less relay, and a copper bar with at least a main part arranged along the side wall of the receiving cavity, and the copper bar is electrically connected to the shell-less relay. Here, it should be explained that the "main part" refers to the part of the copper bar excluding the ends for electrically connecting to other electrical components. "Arranged along the side wall of the receiving cavity" can mean that the main part is attached to the surface of the side wall, or it can also be embedded in the side wall as mentioned below, and the present disclosure does not limit this.

[0043] The shell-less relay refers to the cancellation of the housing and the mounting feet provided on the housing of the traditional shelled relay, and it only includes the core functional part of the relay, thereby effectively reducing its outer contour size. The present disclosure does not limit the specific type and specific structure of the shell-less relay, and it can be adaptively designed according to actual needs.

[0044] The present disclosure does not limit the relay mounting base 100, as long as it can form a receiving cavity for receiving the shell-less relay. The inner contour of the receiving cavity matches the outer contour of the shell-less relay in terms of size and shape to maximize the integration degree of the relay assembly. The relay mounting base 100 can specifically include a substrate and a plurality of vertical plates erected on the substrate, and the plurality of vertical plates enclose to form the "receiving cavity".

[0045] By using the above technical solution, adopting a shell-less relay and installing it in the receiving cavity of the relay mounting base 100 can improve the integration degree of the relay assembly. And because the shell-less relay has a smaller outer contour size compared with the traditional shelled relay, and there is no structure such as mounting feet, the overall occupied space of the relay is reduced, which is beneficial for its layout and installation. In addition, setting at least the main part of the copper bar on the side wall of the receiving cavity further improves the overall integration degree of the relay assembly. And installing the copper bar on the side wall of the receiving cavity can make it closer to the shell-less relay. Compared with arranging the copper bar at intervals outside the relay mounting base 100, it can effectively reduce the required length of the copper bar, and it is more convenient to directly form an electrical connection between the copper bar and the shell-less relay (without setting an electrical connection structure), simplifying the structure of the relay assembly, reducing costs and occupied space.

[0046] In an embodiment of the present disclosure, at least the main part of the copper bar can be embedded in the side wall of the relay mounting base 100. Specifically, in Figure 1 and Figure 3In the illustrated embodiment, the main body portion of the copper busbar can be completely embedded inside the sidewall (the sidewall has a certain thickness), that is, the main body portion of the copper busbar is not directly exposed. This can avoid the copper busbar occupying extra space, which is beneficial to improving the integration of the relay assembly. Moreover, the sidewall "wraps" the outside of the copper busbar, which can prevent the main body portion of the copper busbar from being exposed, reducing risks such as electric leakage and short circuit. During the production process, the copper busbar can be pre-placed in the mold of the sidewall and cast to obtain the sidewall wrapped around the outside of the copper busbar. In addition, in some other embodiments, grooves for embedding the copper busbar can be pre-opened on the sidewall. In this case, at least one side surface of the copper busbar is exposed.

[0047] The present disclosure does not limit the types and quantities of the shell-less relays. For example, in Figures 1 - 3 the illustrated embodiment, the shell-less relay can include a positive relay 210 and a negative relay 220, and the accommodation cavity can include a first accommodation cavity 110 for accommodating the positive relay 210 and a second accommodation cavity 120 for accommodating the negative relay 220. In addition, in some other embodiments, the shell-less relay can also include only one of the positive relay 210 and the negative relay 220.

[0048] Referring to Figure 2 , in the embodiment of the present disclosure, the positive relay 210 can have a first terminal 211 and a second terminal 212, the negative relay 220 can have a third terminal 221 and a fourth terminal 222, and the copper busbar can include: a first DC charging positive copper busbar 310, one end of which is electrically connected to the first terminal 211 and the other end is for electrically connecting to the DC charging busbar 401; a second DC charging positive copper busbar 320, one end of which is electrically connected to the second terminal 212 and the other end is for electrically connecting to the capacitor 402; a first DC charging negative copper busbar 330, one end of which is electrically connected to the third terminal 221 and the other end is for electrically connecting to the DC charging busbar 401; and a second DC charging negative copper busbar 340, one end of which is electrically connected to the fourth terminal 222 and the other end is for electrically connecting to the capacitor 402. Designed in this way, the positive partial circuit of the relay assembly is: DC charging busbar 401 - first DC charging positive copper busbar 310 - positive relay 210 - second DC charging positive copper busbar 320 - capacitor 402; the negative partial circuit of the relay assembly is: DC charging busbar 401 - first DC charging negative copper busbar 330 - negative relay 220 - second DC charging negative copper busbar 340 - capacitor 402.

[0049] The present disclosure does not limit the electrical connection manner between the copper busbar and the corresponding relay or electrical component (such as the DC charging busbar 401, capacitor 402, etc.). For example, the two can be fixed by bolts to achieve electrical connection. In addition, in some other embodiments, electrical connection can also be achieved by welding or other means.

[0050] To fix the positive relay 210 and the negative relay 220, in an embodiment of the present disclosure, the positive relay 210 can be mechanically connected to the first DC charging positive copper bus 310 and the second DC charging positive copper bus 320 through the first terminal 211 and the second terminal 212. For example, the two can be mechanically connected by bolts and electrically connected at the same time. The negative relay 220 can be mechanically connected to the first DC charging negative copper bus 330 and the second DC charging negative copper bus 340 through the third terminal 221 and the fourth terminal 222. For example, the two can be mechanically connected by bolts and electrically connected at the same time. Through the foregoing setting method, there is no need to additionally provide a mechanical fixing structure for the relay, which is beneficial to saving space and reducing assembly parts.

[0051] In some embodiments, the positive relay 210 and the negative relay 220 can also be respectively adhered to the relay mounting seat 100, for example, by potting.

[0052] Referring to Figure 1 , in an embodiment of the present disclosure, the relay assembly may further include: a first adapter copper bus 350, one end of which is electrically connected to one end of the second DC charging positive copper bus 320 far from the second terminal 212, and the other end is used for electrically connecting to the capacitor 402; and a second adapter copper bus 360, one end of which is electrically connected to one end of the second DC charging negative copper bus 340 far from the fourth terminal 222, and the other end is used for electrically connecting to the capacitor 402. By providing the first adapter copper bus 350 and the second adapter copper bus 360 with special structures, it is convenient to transfer the second DC charging positive copper bus 320 and the second DC charging negative copper bus 340 to the capacitor 402 with the least number of copper buses, and it is convenient to realize automatic assembly. In other words, if the second DC charging positive copper bus 320 and the second DC charging negative copper bus 340 are directly extended to the capacitor 402, since one side terminal of itself needs to be docked with the second terminal 212 and the fourth terminal 222, it is difficult for the terminal direction for electrically connecting to the capacitor 402 to directly match the capacitor 402. It needs to change the terminal direction through multiple "bends" to be able to electrically connect to the capacitor 402, and the operation is relatively cumbersome and it is not easy to realize automation. And this kind of "bend" increases the process difficulty, increases the length of the copper bus and the space occupied by the copper bus, which is not conducive to improving the integration of the relay assembly. The present disclosure does not limit the specific structures of the first adapter copper bus 350 and the second adapter copper bus 360, and they can be adaptively designed according to actual situations.

[0053] Referring to Figure 1 and Figure 2, in an embodiment of the present disclosure, the size of the positive relay 210 in the height direction is greater than its size in the width direction and in the length direction; the size of the negative relay 220 in the height direction is greater than its size in the width direction and in the length direction. Here, the height direction refers to the insertion and removal direction when the shell-less relay is installed in the accommodation cavity, that is, the cavity depth direction of the accommodation cavity; the width direction and the length direction refer to the width and length directions of the accommodation cavity, which are perpendicular to the cavity depth direction. With such a design, that is, placing the shell-less relay sideways in the accommodation cavity can save the use of space in the width and length directions, which is beneficial to improving the integration of the relay assembly. In addition, in some other embodiments, for example Figure 3 , the shell-less relay can also be placed horizontally in the accommodation cavity.

[0054] Referring to Figure 1 and Figure 2 , in an embodiment of the present disclosure, the relay assembly may further include a first adapter board 500 for electrically connecting to the main control board 403. Among them, the copper busbar may be formed with a plurality of first conductive members 601 for electrically connecting to the first adapter board 500, such as sampling small copper pieces, conductive pins, etc. With such a design, for example, when the copper busbar includes a first DC charging positive copper busbar 310, a second DC charging positive copper busbar 320, a first DC charging negative copper busbar 330, and a second DC charging negative copper busbar 340, the four copper busbars can be respectively electrically connected to the first adapter board 500 through the first conductive members 601, and the first adapter board 500 is electrically connected to the main control board 403 through a wire harness. Only one wire harness is required to achieve the electrical connection between the four copper busbars and the main control board 403, greatly saving the use of wire harnesses.

[0055] Referring to Figure 1 and Figure 2 , in an embodiment of the present disclosure, the relay assembly may further include a first adapter board 500 for electrically connecting to the main control board 403. Among them, the shell-less relay may be formed with a second conductive member 602 for electrically connecting to the first adapter board 500, such as sampling small copper pieces, conductive pins, etc. With such a design, for example, when the shell-less relay includes a positive relay 210 and a negative relay 220, the two shell-less relays are respectively electrically connected to the first adapter board 500 through the second conductive members 602, and the first adapter board 500 is electrically connected to the main control board 403 through a wire harness. Only one wire harness is required to achieve the electrical connection between the two shell-less relays and the main control board 403, greatly saving the use of wire harnesses.

[0056] In an embodiment of the present disclosure, the first conductive member 601 and the second conductive member 602 may exist simultaneously. Or only one of them may be present.

[0057] Referring to Figures 1 - 3, in an embodiment of the present disclosure, the relay assembly may further include a magnetic ring 404 mounted on the relay mounting seat 100, and the magnetic ring 404 is used for the DC charging bus 401 to pass through. The traditional filter includes a magnetic ring and a mounting and fixing structure for mounting the magnetic ring, and it requires additional installation space. The present disclosure integrates the magnetic ring 404 into the relay mounting seat 100 to achieve the filtering effect. Compared with the traditional method, it reduces the number of internal parts, improves the space utilization rate and the integration degree of the assembly.

[0058] Referring to Figures 4 - 6 , according to the second aspect of the present disclosure, a motor controller is provided, including a box body 405, a main control board 403 accommodated in the box body 405, a capacitor 402 accommodated in the box body 405, and the above-mentioned relay assembly. Since this motor controller has all the beneficial effects of the above-mentioned relay assembly, it will not be elaborated here.

[0059] Referring to Figure 4 , in some embodiments, the motor controller may further include a box cover 406 for covering the box body 405.

[0060] In order to realize the three-phase current sampling of the motor controller, referring to Figures 8 - 10 , in an embodiment of the present disclosure, the motor controller may further include a silicon steel sheet 407 for concentrating the magnetic field of the copper bar and a Hall chip 408 for sensing the magnetic field. The Hall chip 408 is electrically connected to the main control board 403. The main control board 403 obtains the current information by analyzing the magnetic field information. Among them, the silicon steel sheet 407 and the Hall chip 408 can be separately arranged. On the one hand, the split design is self-assembled during production, and the cost is lower than that of the integrated Hall element. On the other hand, the split design is beneficial to integrating the silicon steel sheet 407 and the Hall chip 408 into the existing components of the motor controller respectively, avoiding additional space occupation and making the installation more flexible.

[0061] The present disclosure does not limit the specific installation positions of the silicon steel sheet 407 and the Hall chip 408. In an embodiment of the present disclosure, the motor controller may further include a driver 409. Among them, referring to Figure 8 , the Hall chip 408 may be integrated on the upper surface of the driver 409; or referring to Figure 9 , the Hall chip 408 may be integrated on the lower surface of the driver 409; or referring to Figure 10 , the motor controller may further include a second adapter board 410 arranged on the lower side of the driver 409, and the Hall chip 408 may be integrated on the second adapter board 410. By arranging the Hall chip 408 at different positions, different-precision current sampling can be achieved, so that the position of the Hall chip 408 can be adaptively configured according to requirements. For example Figure 9 The scheme shown in Figure 8 The scheme shown can improve the accuracy by 7%,Figure 10 Shown scheme comparison Figure 9 The shown scheme can increase the accuracy by 10.5%.

[0062] Refer to Figure 4 , in the embodiment of the present disclosure, the motor controller may further include a fuse element 411, and the fuse element 411 may be integrated into the capacitor 402. With such a design, the use of a fuse fixing base to fix the fuse element 411 is reduced, and the number of internal parts of the motor controller is decreased.

[0063] Refer to Figure 5 , in the embodiment of the present disclosure, the box body 405 may be provided with a water inlet pipe 610 and a water outlet pipe 620. The water inlet pipe 610 may be used to connect to a cooling water source, and the water outlet pipe 620 is used to connect to the water inlet of the motor 700. Among them, at least one of the water inlet pipe 610 and the water outlet pipe 620 may be integrally formed with the box body 405. With such a design, making at least one of the water inlet pipe 610 and the water outlet pipe 620 integrally formed with the box body 405 can reduce the use of parts and improve production efficiency. When both the water inlet pipe 610 and the water outlet pipe 620 are integrally formed with the box body 405, the box body 405, the water inlet pipe 610, and the water outlet pipe 620 may be made of the same material, such as all being made of plastic material, metal material, etc., and integrally injection molded during manufacturing.

[0064] In the embodiment of the present disclosure, for the cooling circuit, the coolant entering from the water inlet pipe 610 first cools the transformer and inductor of the power supply, then enters the electronic control to cool the IGBT, and then passes through the rubber hose from the electronic control water outlet pipe 620 to connect to the water inlet of the motor to make the coolant enter the motor. Finally, the coolant enters the vehicle cooling circuit from the water outlet of the motor.

[0065] Refer to Figure 6 , in the embodiment of the present disclosure, at least a part of the box body 405 may be used to extend downward between the motor 700 and the reducer 800. With such a design, the space above the transmission half shaft connected between the motor 700 and the reducer 800 can be effectively utilized, improving the space utilization rate.

[0066] Further, refer to Figure 6 , in the embodiment of the present disclosure, fastening holes 910 may be respectively provided on the end faces of the part of the box body 405 extending between the motor 700 and the reducer 800 facing the motor 700 and the reducer 800 for respectively fastening connections with the motor 700 and the reducer 800. Support the box body 405 from two sides to ensure the strength, dynamic stiffness, and modal requirements of the motor controller. And setting the fastening holes 910 on the box body 405 is more conducive to the installation of fasteners and avoids interference with the power supply at the bottom of the box body 405.

[0067] Refer to Figure 7, in an embodiment of the present disclosure, the housing 405 may be provided with a first opening for installing the three-phase magnetic ring fixing seat 412 and a second opening for installing the resolver harness 413. Wherein, a first sealing ring 920 may be provided between the three-phase magnetic ring fixing seat 412 and the housing 405, and a second sealing ring 930 may be provided between the resolver harness 413 and the housing 405. By sealing these two places, it can effectively prevent the hot steam generated during the operation of the motor from entering the housing 405 of the motor controller, prevent the condensation of the hot steam with temperature difference, and prevent water droplets from falling on the main control board 403 and other short-circuit failures.

[0068] According to a third aspect of the present disclosure, a powertrain is provided, including a motor 700, a reducer 800, and the above-mentioned motor controller. Since this powertrain has all the beneficial effects of the above-mentioned motor controller, they will not be elaborated here.

[0069] According to a fourth aspect of the present disclosure, a vehicle is provided, including the above-mentioned powertrain. Since this vehicle has all the beneficial effects of the above-mentioned powertrain, they will not be elaborated here.

[0070] The preferred embodiments of the present disclosure have been described in detail above in conjunction with the accompanying drawings. However, the present disclosure is not limited to the specific details in the above embodiments. Within the scope of the technical concept of the present disclosure, various simple modifications can be made to the technical solutions of the present disclosure, and these simple modifications all fall within the protection scope of the present disclosure.

[0071] In addition, it should be noted that, among the various specific technical features described in the above specific embodiments, they can be combined in any suitable manner without conflict. To avoid unnecessary repetition, the present disclosure will not separately describe various possible combination methods.

[0072] In addition, any combination can be made between various different embodiments of the present disclosure, as long as it does not violate the idea of the present disclosure, it should also be regarded as the content disclosed by the present disclosure.

Claims

1. A relay assembly, characterized in that: include: Caseless relay; A relay mounting seat having an accommodating cavity for accommodating the caseless relay; as well as A copper busbar, at least a main body of which is arranged along the side wall of the accommodating cavity, and the copper busbar is electrically connected to the caseless relay.

2. The relay assembly according to claim 1, characterized in that: At least a main body portion of the copper busbar is embedded in a side wall of the relay mounting seat.

3. The relay assembly according to claim 1 or 2, characterized in that: The caseless relay includes a positive pole relay and a negative pole relay, and the accommodating cavity includes a first accommodating cavity for accommodating the positive pole relay and a second accommodating cavity for accommodating the negative pole relay.

4. The relay assembly according to claim 3, characterized in that: The positive relay has a first terminal and a second terminal, the negative relay has a third terminal and a fourth terminal, and the copper busbar includes: A first DC charging positive copper bar, one end of which is electrically connected to the first terminal, and the other end of which is used to be electrically connected to the DC charging busbar; A second DC charging positive copper bar, one end of which is electrically connected to the second terminal and the other end of which is used to electrically connect to the capacitor; A first DC charging negative copper bar, one end of which is electrically connected to the third terminal, and the other end of which is used to electrically connect to the DC charging busbar; and A second DC charging negative electrode copper bar has one end electrically connected to the fourth terminal and the other end used to electrically connect to the capacitor.

5. The relay assembly according to claim 4, characterized in that: The positive relay is mechanically connected to the first DC charging positive copper bar and the second DC charging positive copper bar through the first terminal and the second terminal; the negative relay is mechanically connected to the first DC charging negative copper bar and the second DC charging negative copper bar through the third terminal and the fourth terminal.

6. The relay assembly according to claim 5, characterized in that: The positive relay and the negative relay are respectively adhered to the relay mounting seat.

7. The relay assembly according to claim 4, characterized in that: Also includes: a first transfer copper bar, one end of which is electrically connected to an end of the second DC charging positive copper bar away from the second terminal, and the other end of which is used to electrically connect to the capacitor; as well as A second transfer copper bar has one end electrically connected to an end of the second DC charging negative electrode copper bar away from the fourth terminal, and the other end is used to electrically connect to the capacitor.

8. The relay assembly according to claim 3, characterized in that: The height dimension of the positive relay is larger than the width dimension and the length dimension; the height dimension of the negative relay is larger than the width dimension and the length dimension.

9. The relay assembly according to claim 1, characterized in that: It also includes a first adapter board for electrically connecting to a main control board, wherein the copper busbar is formed with a plurality of first conductive members electrically connected to the first adapter board, and / or the caseless relay is formed with a second conductive member electrically connected to the first adapter board.

10. The relay assembly according to claim 1, characterized in that: It also includes a magnetic ring installed on the relay mounting seat, and the magnetic ring is used for the DC charging bus to pass through.

11. A motor controller, characterized in that: The invention comprises a box body, a main control board accommodated in the box body, a capacitor accommodated in the box body and a relay assembly according to any one of claims 1 to 10.

12. The motor controller according to claim 11, characterized in that: It also includes a silicon steel sheet for gathering the magnetic field of the copper busbar and a Hall chip for sensing the magnetic field, wherein the Hall chip is electrically connected to the main control board. Wherein, the silicon steel sheet and the Hall chip are separately arranged.

13. The motor controller according to claim 12, characterized in that: The motor controller further comprises a driver, Wherein, the Hall chip is integrated on the upper surface of the driver; or the Hall chip is integrated on the lower surface of the driver; or the motor controller further includes a second adapter board arranged on the lower side of the driver, and the Hall chip is integrated on the second adapter board.

14. The motor controller according to claim 11, characterized in that: A fuse element is also included, and the fuse element is integrated with the capacitor.

15. The motor controller according to claim 11, characterized in that: The box body is provided with a water inlet pipe and a water outlet pipe, the water inlet pipe is used to connect to a cooling water source, and the water outlet pipe is used to connect to a water inlet of the motor. Wherein, at least one of the water inlet pipe and the water outlet pipe is integrally formed with the box body.

16. The motor controller according to claim 11, characterized in that: At least a portion of the box is used to extend downward between the motor and the reducer.

17. The motor controller according to claim 16, characterized in that: The end surfaces of the portion of the box body extending between the motor and the reducer and facing the motor and the reducer are respectively provided with fastening holes for fastening and connecting with the motor and the reducer respectively.

18. The motor controller according to claim 11, characterized in that: The box body is provided with a first opening for installing a three-phase magnetic ring fixing seat and a second opening for installing a resolver wiring harness. Wherein, a first sealing ring is arranged between the three-phase magnetic ring fixing seat and the box body, and a second sealing ring is arranged between the resolver wiring harness and the box body.

19. A powertrain, characterized in that: It comprises a motor, a reducer and a motor controller as described in any one of claims 11-18.

20. A vehicle, characterized in that: Includes the powertrain as described in claim 19.

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