Integrated Boost dual-motor controller

Abstract

The utility model relates to an integrated Boost dual-motor controller, which comprises a shell, an energy distribution assembly and a Boost circuit, the energy distribution assembly and the Boost circuit are fixed in the shell, the shell is provided with a charging port and a battery bus port, and the energy distribution assembly comprises a first relay, a second relay and a third relay; a certain electrode of the charging port is connected with an electrode corresponding to a battery bus port through a third relay, the other electrode of the charging port is connected with an electrode corresponding to the battery bus port through a second relay, the first relay is connected with a Boost circuit in series and then connected with the second relay in parallel, and the second relay is triggered to be closed by high voltage; and the first relay is triggered to be closed by medium and low voltage. Compared with the prior art, the utility model has the advantages of high integration level, high space utilization rate and the like on the integration of the middle-high voltage direct current quick charging function.

Description

Technical Field

[0001] The utility model relates to the field of new energy vehicles, in particular to an integrated Boost boost dual motor controller. Background Art

[0002] With the rapid development of new energy vehicle technology, high-performance and highly integrated electric drive systems have become the mainstream development direction in the market. As an important part of the power assembly of the electric drive system, a highly integrated solution with multiple functions is an inevitable development trend for motor controllers. Especially in the leading original equipment manufacturers (OEMs) in the new energy vehicle industry, the demand for high-integration multi-in-one drive motor controllers for high-performance version vehicles is extremely urgent.

[0003] In recent years, in the main models promoted by OEMs, dual electric drive system power assemblies have been set to meet the higher power output performance of vehicles. For corresponding dual drive motor units, dual controllers are essential. In the conventional solution, according to the layout of drive motors in the vehicle, two independent controllers are installed separately to drive the dual motors respectively, which results in excessive occupation of the space volume in the engine compartment and is not conducive to the vehicle's requirements for miniaturization and integration of the power assembly. Secondly, two independent dual controller units require two sets of independent electronic control casings, cooling systems and corresponding connection wire harnesses, which will undoubtedly greatly increase the manufacturing cost of the drive controller. Moreover, due to the low integration level of the two independent controller systems, it is unlikely to integrate the fast charging function of the vehicle. A PDU unit needs to be newly established in the engine compartment to physically connect the fast charging network and the dual electronic control high-voltage network, which will further reduce the space utilization rate of the vehicle engine compartment. This is contradictory to the requirements for integration and miniaturization of the power assembly in the engine compartment. In particular, in recent years, large storage boxes have been installed in the engine compartments of mainstream models, so it is necessary to improve the space utilization rate in the engine compartment to make more space for the storage box.

[0004] In addition, the power assembly of the 800V to 1000V high-voltage platform has also become an important direction for market development. However, the existing fast charging stations in the market are generally medium-voltage charging piles of 350V to 500V, so it is necessary to integrate a boost circuit inside the motor controller to achieve compatibility with medium- and high-voltage power platforms. Therefore, there is an urgent need to develop a highly integrated high-voltage dual motor controller for new energy vehicles, which integrates a BOOST boost circuit to achieve compatibility with the existing medium- and high-voltage charging networks in the market. Summary of the Utility Model

[0005] The purpose of the utility model is to overcome the defects existing in the above-mentioned prior art.

[0006] The purpose of the utility model can be achieved by the following technical solutions:

[0007] An integrated Boost boost dual-motor controller includes a housing, as well as an energy distribution component and a Boost boost circuit fixed inside the housing. A charging port and a battery bus port are provided on the housing. The energy distribution component includes a first relay, a second relay, and a third relay;

[0008] One electrode of the charging port is connected to the corresponding electrode of the battery bus port through the third relay, and the other electrode of the charging port is connected to the corresponding electrode of the battery bus port through the second relay. The first relay is connected in parallel with the second relay after being connected in series with the Boost boost circuit. The second relay is triggered to close by high voltage; the first relay is triggered to close by medium and low voltage.

[0009] Preferably, the controller further includes a dual-capacitor filtering component. The dual-capacitor filtering component includes a left filter capacitor module and a right filter capacitor module. The right filter capacitor module and the left filter capacitor are of a symmetric structure, and the dual-capacitor filtering component is in an I shape; the left filter capacitor module includes an EMC filtering device, an input busbar, and an output busbar. The EMC filtering device is fixed on the input busbar and is electrically connected to the input busbar. The input end of the input busbar is connected to the battery bus port, and the output end is connected to the output busbar.

[0010] Preferably, the EMC filtering device includes a first-stage magnetic core, a second-stage magnetic core, an X capacitor, a Y capacitor, and a pressing plate. Both the first-stage magnetic core and the second-stage magnetic core are of a splicing structure of a C-shaped ferrite and an I-shaped ferrite. The input busbar passes through the first-stage magnetic core and the second-stage magnetic core in sequence. An X capacitor slot and a Y capacitor slot are respectively provided on both sides of the input busbar. The X capacitor is fixed in the X capacitor slot, and the Y capacitor is fixed in the Y capacitor slot. The X capacitor and the Y capacitor are electrically connected to the input busbar.

[0011] Preferably, the Boost boost circuit includes a Boost boost module, a first motor winding, and a first half-bridge inverter module connected in sequence; one end of the first relay is the charging port, and the other end is connected to the Boost boost module. The other end of the first half-bridge module is connected to the battery bus port.

[0012] Preferably, the controller further includes a second half-bridge inverter module. Two inverter bridge heat dissipation slots are symmetrically provided inside the housing. The first half-bridge inverter module and the second half-bridge inverter module are respectively fixed in the inverter bridge heat dissipation slots on both sides; the inverter bridge heat dissipation slot includes a plurality of connected heat dissipation cavities, and the heat dissipation cavities are connected with a cooling channel.

[0013] Preferably, the cooling channels are formed on the back surface of the housing. The cooling channels include a liquid inlet, a liquid outlet, a first sub-channel, and a second sub-channel. The first sub-channel and the second sub-channel are in parallel. One ends of the first sub-channel and the second sub-channel are commonly connected to the liquid inlet, and the other ends are commonly connected to the liquid outlet. The first sub-channel passes through the inverter bridge heat dissipation groove under the first half-bridge inverter module, and the second sub-channel passes through the inverter bridge heat dissipation groove under the second half-bridge inverter module.

[0014] Preferably, a water channel cover plate is further provided on the side of the housing where the cooling channels are provided. The water channel cover plate and the housing are sealed by friction welding.

[0015] Preferably, the Boost boost module includes a current guiding row, a boost inductor, and a current sensor connected in sequence. The current guiding row is connected to a first relay, and the current sensor is connected to a first motor winding. An inductor heat dissipation cavity is provided on the housing, and the Boost boost module is fixed in the inductor heat dissipation cavity.

[0016] Preferably, the Boost boost module is fixed in the inductor heat dissipation cavity by epoxy potting.

[0017] Preferably, the controller further includes a four-phase busbar. The four-phase busbar includes a U copper bar, a V copper bar, a W copper bar, and a boost copper bar. There are 3 potting grooves provided on the plastic shell covering the outside of the four-phase busbar. Induction iron cores are provided in the potting grooves, and Hall induction grooves are provided at the upper ends of the potting grooves. Electronic chips for monitoring the currents on the U copper bar, the V copper bar, and the W copper bar are embedded in the Hall induction grooves.

[0018] Compared with the prior art, the present utility model has the following advantages:

[0019] (1) In the battery charging stage of this solution, the external grid current enters the energy distribution component from the charging port, and then the external voltage level is identified. When the external voltage is a high voltage, the first relay is disconnected, and the second relay and the third relay are closed, and the current directly flows into the battery busbar end for charging. When the external voltage is a medium or low voltage, the second relay is disconnected, and the first relay and the third relay are closed. After passing through the Boost boost circuit, the medium or low voltage is boosted, and then flows through the high-voltage busbar to the battery busbar port for charging.

[0020] By directly combining the externally input high voltage to the battery busbar end, and boosting the externally input medium or low voltage and then combining it to the battery busbar end, the dual-motor controller realizes the integration of the medium and high voltage DC fast charging function. In this way, it is possible to achieve the compatibility of vehicles with high-voltage platforms such as 800V with the existing medium and high voltage charging networks in the market, and has great market application prospects and high market promotion value.

[0021] (2) This solution internally integrates a symmetric filter capacitor module, integrating the DC support capacitor with multi-stage magnetic cores, X capacitors, and Y capacitors. It achieves EMC performance above class 3 for dual motor controllers within a small volume, with good electromagnetic compatibility performance.

[0022] (3) This solution adopts a half-bridge inverter module and a dual-capacitor filtering component, and through a flat layout with left-right symmetry of dual electric controls, it realizes a flattened structural integration solution for dual electric controls, reducing the size of the controller in the height direction, thus creating more space for the vehicle engine compartment. It can well meet the layout requirements of current vehicle manufacturers for setting up a large storage compartment within the engine compartment, with the characteristics of high integration and low height.

[0023] (4) This solution considers that the number of heat-generating devices inside the dual electric controls has doubled compared to the single electric control, and the heat generation has also increased exponentially. Therefore, a parallel water-cooling channel structure system is provided inside the dual electric controls. The coolant flows through the first channel and the second channel respectively from the liquid inlet, and converges and flows out at the liquid outlet, which not only reduces the flow resistance of the cooling system but also improves the heat dissipation effect of the half-bridge inverter module. At the same time, the parallel water channel system inside the controller housing has dense flow channels and also has a good heat dissipation effect on the housing of the dual electric controls. Subsequently, the boost boost module integrated inside the housing also realizes indirect heat dissipation, with excellent heat dissipation and cooling performance. Description of the Drawings

[0024] Figure 1 is the electrical schematic diagram of the integrated Boost boost dual motor controller provided by the present utility model;

[0025] Figure 2 is the exploded view of the structure of the integrated Boost boost dual motor controller provided by the present utility model;

[0026] Figure 3 is the structural schematic diagram of the dual-capacitor filtering component provided by the present utility model;

[0027] Figure 4 is Figure 3 the enlarged view at A in

[0028] Figure 5 is the structural schematic diagram of the left filter capacitor module provided by the present utility model;

[0029] Figure 6 is the structural schematic diagram of the energy distribution component provided by the present utility model;

[0030] Figure 7 is the electrical schematic diagram of the energy distribution component provided by the present utility model;

[0031] Figure 8 is the exploded view of the structure of the energy distribution component provided by the present utility model;

[0032] Figure 9 The structural schematic diagram of the Boost boost module provided by the present utility model;

[0033] Figure 10 The structural explosion diagram of the four-phase busbar provided by the present utility model;

[0034] Figure 11 is Figure 10 The enlarged view at position B in

[0035] Figure 12 The structural schematic diagram of the first perspective of the base provided by the present utility model;

[0036] Figure 13 The structural schematic diagram of the second perspective of the base provided by the present utility model;

[0037] In the figure: 1. Shell, 11. Charging port, 12. Battery busbar port, 13. Inverter bridge heat dissipation slot, 14. Inductor heat dissipation cavity; 2. Energy distribution component, 21. First relay, 22. Second relay, 23. Third relay; 3. Boost boost circuit, 31. Boost boost module, 311. Current guiding row, 312. Boost inductor, 313. Current sensor 32. First motor winding, 33. First half-bridge inverter module, 4. Double-capacitor filtering component, 41. Input busbar, 42. Output busbar, 43. First-stage magnetic core, 44. Second-stage magnetic core, 45. X capacitor, 46. Y capacitor, 47. Pressure plate, 48. X capacitor slot, 49. Y capacitor slot; 5. Second half-bridge inverter module; 6. Four-phase busbar, 61. U copper row, 62. V copper row, 63. W copper row, 64. Boost copper row, 65. Potting slot, 66. Induction iron core, 67. Hall induction slot. Specific embodiments

[0038] To make the objectives, technical solutions and advantages of the embodiments of the present utility model clearer, the technical solutions in the embodiments of the present utility model will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present utility model. Obviously, the described embodiments are some but not all of the embodiments of the present utility model. Usually, the components of the embodiments of the present utility model described and illustrated herein can be arranged and designed in various different configurations.

[0039] Therefore, the following detailed description of the embodiments of the present utility model provided in the drawings is not intended to limit the scope of the present utility model to be protected, but merely represents the selected embodiments of the present utility model. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present utility model without creative efforts shall fall within the scope of protection of the present utility model.

[0040] It should be noted that like reference numerals and letters denote like items in the following figures, and thus, once an item is defined in one figure, it need not be further defined and explained in subsequent figures.

[0041] In the description of the present utility model, it should be noted that the orientation or positional relationship indicated by the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. is based on the orientation or positional relationship shown in the figures, or the orientation or positional relationship in which the utility model product is customarily placed during use. It 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 thus should not be construed as a limitation on the present utility model.

[0042] It should be noted that the terms "first" and "second" are only used for descriptive purposes and should not be construed as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include one or more of such features. In the description of the present application, "a plurality" means two or more, unless otherwise specifically defined.

[0043] In addition, terms such as "horizontal" and "vertical" do not mean that the components are required to be absolutely horizontal or hanging vertically, but may be slightly inclined. For example, "horizontal" only means that its direction is more horizontal relative to "vertical", and does not mean that the structure must be completely horizontal, but may be slightly inclined.

[0044] Embodiment 1

[0045] As Figure 1 、 Figure 2 、 Figures 6 to 8 shown, this embodiment provides an integrated Boost boost dual-motor controller, which includes a housing 1 and a power distribution component 2 and a Boost boost circuit 3 fixed inside the housing 1. A charging port 11 and a battery bus port 12 are provided on the housing 1. The power distribution component 2 includes a first relay 21, a second relay 22, and a third relay 23;

[0046] One electrode of the charging port 11 is connected to the corresponding electrode of the battery bus port 12 through the third relay 23, and the other electrode of the charging port 11 is connected to the corresponding electrode of the battery bus port 12 through the second relay 22. The first relay 21 is connected in parallel with the second relay 22 after being connected in series with the Boost boost circuit 3. The second relay 22 is triggered to close by high voltage; the first relay 21 is triggered to close by medium and low voltage.

[0047] Working principle: During the charging stage, the current from the external power grid enters the power distribution component 2 through the charging port 11, and then the external voltage level is identified. When the external voltage is high voltage, the first relay 21 is disconnected, and the second relay 22 and the third relay 23 are closed, and the current directly flows into the battery bus terminal for charging. When the external voltage is medium or low voltage, the second relay 22 is disconnected, and the first relay 21 and the third relay 23 are closed. After passing through the Boost boost circuit 3, the medium or low voltage is boosted, and then flows through the high-voltage bus to the battery bus port 12 for charging.

[0048] By directly connecting the externally input high voltage to the battery bus terminal, boosting the externally input medium or low voltage, and then connecting it to the battery bus terminal, the dual-motor controller realizes the integration of the medium and high-voltage DC fast charging function. In this way, it is possible to achieve compatibility of high-voltage platform vehicles such as 800V with the existing medium and high-voltage charging networks in the market, which has great market application prospects and high market promotion value.

[0049] Preferred implementation manner, as Figures 3 to 5 shown, the controller further includes a dual-capacitor filtering component 4. The dual-capacitor filtering component 4 includes a left filtering capacitor module and a right filtering capacitor module. The right filtering capacitor module and the left filtering capacitor are symmetric structures, and the dual-capacitor filtering component is in an I shape. The left filtering capacitor module includes an EMC filtering device, an input busbar 41, and an output busbar 42. The EMC filtering device is fixed on the input busbar 41 and is electrically connected to the input busbar 41. The input end of the input busbar 41 is connected to the battery bus port 12, and the output end is connected to the output busbar 42.

[0050] Furthermore, the EMC filtering device includes a first-stage magnetic core 43, a second-stage magnetic core 44, an X capacitor 45, a Y capacitor 46, and a pressing plate 47. Both the first-stage magnetic core 43 and the second-stage magnetic core 44 are splicing structures of C-shaped ferrite and I-shaped ferrite. The input busbar 41 passes through the first-stage magnetic core 43 and the second-stage magnetic core 44 in sequence. X capacitor slots 48 and Y capacitor slots 49 are respectively arranged on both sides of the input busbar 41. The X capacitor 45 is fixed in the X capacitor slot 48, and the Y capacitor 46 is fixed in the Y capacitor slot 49. The X capacitor 45 and the Y capacitor 46 are electrically connected to the input busbar 41.

[0051] Adopting a half-bridge inverter module and a dual-capacitor filtering component, through the flat layout of the dual-electronic control with left-right symmetry, a flat structure integration scheme of the dual-electronic control is realized, reducing the size of the controller in the height direction, thereby creating more space for the engine compartment of the whole vehicle, and being able to well meet the layout requirements of the current vehicle manufacturers for setting up a large storage compartment in the engine compartment, with the characteristics of high integration and low height.

[0052] It internally integrates a symmetric filter capacitor module, integrates the DC support capacitor with a multi-stage magnetic core, X capacitor, and Y capacitor, and realizes EMC performance above class 3 for the dual-motor controller in a small volume space, with good electromagnetic compatibility performance.

[0053] Specifically, the Boost boost circuit 3 includes a Boost boost module 31, a first motor winding 32, and a first half-bridge inverter module 33 connected in sequence; one end of the first relay 21 is connected to the charging port 11, and the other end is connected to the Boost boost module 31, and the other end of the first half-bridge module 33 is connected to the battery bus port 12.

[0054] Preferred implementation mode, such as Figure 12 and Figure 13 As shown, the controller further includes a second half-bridge inverter module 5. Two inverter bridge heat dissipation slots 13 are symmetrically arranged in the housing 1. The first half-bridge inverter module 33 and the second half-bridge inverter module 5 are respectively fixed in the inverter bridge heat dissipation slots 13 on both sides; the inverter bridge heat dissipation slot 13 includes a plurality of connected heat dissipation cavities, and the heat dissipation cavities are connected with a cooling channel.

[0055] Furthermore, the cooling channel is opened on the back of the housing 1. The cooling channel includes a liquid inlet, a liquid outlet, a first sub-channel, and a second sub-channel. The first sub-channel and the second sub-channel are in parallel. One ends of the first sub-channel and the second sub-channel are commonly connected to the liquid inlet, and the other ends are commonly connected to the liquid outlet. The first sub-channel passes through the inverter bridge heat dissipation slot 13 under the first half-bridge inverter module 33, and the second sub-channel passes through the inverter bridge heat dissipation slot 13 under the second half-bridge inverter module 5.

[0056] Among them, a water channel cover plate is also provided on the side of the housing 1 where the cooling channel is provided, and the water channel cover plate and the housing 1 are sealed by friction welding.

[0057] A parallel heat dissipation water channel structure system is provided inside the double electric control. The coolant flows through the first channel and the second channel respectively from the liquid inlet and converges and flows out at the liquid outlet, which not only reduces the flow resistance of the cooling system but also improves the heat dissipation effect of the half-bridge inverter module. At the same time, the parallel water channel system inside the controller housing has a dense flow channel and also has a good heat dissipation effect on the double electric control housing. Subsequently, the boost boost module integrated inside the housing also realizes indirect heat dissipation, with excellent heat dissipation and cooling performance.

[0058] Such as Figure 9As shown, the Boost boost module 31 includes a current guiding row 311, a boost inductor 312, and a current sensor 313 connected in sequence. The current guiding row 311 is connected to the first relay 21, and the current sensor 313 is connected to the first motor winding 32. An inductor heat dissipation cavity 14 is provided on the housing 1, and the Boost boost module 31 is fixed in the inductor heat dissipation cavity 14. The Boost boost module 31 is fixed in the inductor heat dissipation cavity 14 by means of epoxy potting.

[0059] As Figure 10 and Figure 11 shown, the controller further includes a four-phase busbar 6. The four-phase busbar 6 includes a U copper bar 61, a V copper bar 62, a W copper bar 63, and a boost copper bar 64. There are 3 potting grooves 65 on the plastic-coated shell outside the four-phase busbar 6. An induction iron core 66 is provided in the potting groove 65, and a Hall induction groove 67 is provided at the upper end of the potting groove 65. An electronic chip for monitoring the current on the U copper bar 61, V copper bar 62, and W copper bar 63 is embedded in the Hall induction groove 67.

[0060] Combined with the above preferred embodiments, this embodiment also provides a more specific implementation manner. As Figures 1 to 13 shown, an integrated Boost boost dual-motor controller includes a housing 1, an energy distribution component 2, a Boost boost module 31, a first half-bridge inverter module 33, a second half-bridge inverter module 5, a dual-capacitor filtering component 4, a first integrated drive circuit board, a second integrated drive circuit board, two four-phase busbars 6, and a cover plate;

[0061] In the driving stage, the current passes through the battery busbar port, flows through the dual-capacitor filtering component, and then reaches the half-bridge inverter module 1 and the half-bridge inverter module 2 respectively to drive two motors; in the charging stage, the external grid current enters the high-voltage energy distribution component from the fast charging end, and then the external voltage level is identified. When the external voltage is high voltage, the relay 1 is disconnected, and the relay 2 and the relay 3 are closed, and the current directly flows into the battery busbar end for charging; when the external voltage is medium or low voltage, the relay 2 is disconnected, and the relay 1 and the relay 3 are closed. The Boost boost circuit composed of the boost inductor, the motor winding 1, and the half-bridge inverter module 1 boosts the medium or low voltage, and then flows through the high-voltage bus to the battery busbar end for charging.

[0062] The dual-capacitor filtering component is divided into a left filtering capacitor module and a right filtering capacitor module. The left filtering capacitor module internally integrates an EMC filtering device, an input busbar, and an output busbar. The EMC filtering device includes a primary magnetic core, a secondary magnetic core, an X capacitor, a Y capacitor, and a pressing plate. The primary magnetic core and the secondary magnetic core are "C"-shaped and "I"-shaped ferrites. The input busbar passes through the primary magnetic core and the secondary magnetic core. The X capacitor and the Y capacitor are arranged in the X capacitor slot and the Y capacitor slot adjacent to the input busbar and are electrically connected to the input busbar. The right filtering capacitor module has a symmetrical structure with the left filtering capacitor, and the overall dual-capacitor filtering component is in the shape of a "work" character.

[0063] The high-voltage power distribution component includes a base 24, a first relay, a second relay, a third relay, and a power distribution busbar 25. The relays and the busbar are electrically connected according to the Figure 7 electrical schematic diagram shown. When a high voltage is input at the fast charging end, relays 2 and 3 are closed to achieve electrical connection between the fast charging end and the battery busbar end; when a medium or low voltage is input at the fast charging end, relays 1 and 3 are closed to electrically connect the voltage at the fast charging end to the boost end of the Boost boost circuit.

[0064] The housing is a flattened aluminum alloy box. There are two inverter bridge heat dissipation slots in the dual-electronic control housing, which are respectively used for the installation and cooling of the first inverter bridge module and the second inverter bridge module. Each inverter bridge heat dissipation slot is composed of 3 square heat dissipation cavities, and each heat dissipation cavity communicates with the first sub-channel or the second sub-channel at the bottom of the box. An inductor heat dissipation cavity is provided at the lower left corner of the dual-electronic control housing. The boost inductor of the Boost boost module is fixed in the inductor heat dissipation cavity by epoxy potting. A cooling channel is provided on the back of the dual-electronic control housing and is sealed by friction stir welding with the water channel cover plate to the dual-electronic control volume. The cooling channel is divided into a first sub-channel and a second sub-channel, and the first sub-channel and the second sub-channel are respectively directly below the two inverter bridge heat dissipation slots.

[0065] The coolant enters the dual-electronic control housing through the inlet and is divided into two paths to flow to the first channel and the second channel respectively, and finally converges at the coolant outlet position to form a parallel cooling circuit. The Boost boost module is composed of a boost inductor, a current guiding row, and a current sensor. The current of the medium and low voltage platform flows into the boost inductor through the current guiding row, and then flows out of the boost inductor and passes through the current sensor to achieve the detection of the boost current.

[0066] The four-phase busbar is a plastic-coated part of plastic and copper busbars and integrates the function of a current sensor. It internally includes a U copper busbar, a V copper busbar, a W copper busbar, and a boost copper busbar. Potting grooves are respectively provided on the plastic-coated plastic shells outside the U copper busbar, the V copper busbar, and the W copper busbar. The induction iron core is fixed in the potting grooves of the plastic shell. A Hall induction groove is provided at the upper end of the potting groove, and the electronic chip on the integrated circuit board is embedded into the Hall induction groove, thereby realizing the current monitoring of the U copper busbar, the V copper busbar, and the W copper busbar.

[0067] The preferred specific embodiments of the present utility model have been described in detail above. It should be understood that those of ordinary skill in the art can make many modifications and variations based on the concept of the present utility model without creative efforts. Therefore, all technical solutions that can be obtained by those skilled in the art in this technical field based on the concept of the present utility model through logical analysis, reasoning, or limited experiments on the basis of the prior art shall fall within the protection scope determined by the claims.

Claims

1. An integrated Boost dual-motor controller, characterized in that: The invention comprises a housing (1), an energy distribution component (2) and a Boost circuit (3) fixed inside the housing (1), the housing (1) being provided with a charging port (11) and a battery bus port (12), the energy distribution component (2) comprising a first relay (21), a second relay (22) and a third relay (23); One electrode of the charging port (11) is connected to the corresponding electrode of the battery bus port (12) through a third relay (23), and the other electrode of the charging port (11) is connected to the corresponding electrode of the battery bus port (12) through a second relay (22); the first relay (21) is connected in series with a Boost circuit (3) and then connected in parallel with the second relay (22); the second relay (22) is triggered to close by a high voltage, and the first relay (21) is triggered to close by a medium or low voltage.

2. The integrated Boost dual-motor controller according to claim 1, characterized in that: The controller further comprises a dual-capacitor filter assembly (4), the dual-capacitor filter assembly (4) comprising a left filter capacitor module and a right filter capacitor module, the right filter capacitor module and the left filter capacitor being of symmetrical structure, and the dual-capacitor filter assembly is in an I-shape; the left filter capacitor module comprises an EMC filter element, an input bus (41) and an output bus (42), the EMC filter element is fixed on the input bus (41) and electrically connected to the input bus (41), the input end of the input bus (41) is connected to the battery bus port (12), and the output end is connected to the output bus (42).

3. The integrated Boost dual-motor controller according to claim 2, characterized in that: The EMC filter device comprises a primary magnetic core (43), a secondary magnetic core (44), an X capacitor (45), a Y capacitor (46) and a pressure plate (47); the primary magnetic core (43) and the secondary magnetic core (44) are both C-shaped ferrite and I-shaped ferrite splicing structures; the input bus (41) passes through the primary magnetic core (43) and the secondary magnetic core (44) in sequence; an X capacitor slot (48) and a Y capacitor slot (49) are respectively provided on both sides of the input bus (41); the X capacitor (45) is fixed in the X capacitor slot (48); the Y capacitor (46) is fixed in the Y capacitor slot (49); and the X capacitor (45) and the Y capacitor (46) are electrically connected to the input bus (41).

4. The integrated Boost dual-motor controller according to claim 1, characterized in that: The Boost circuit (3) comprises a Boost module (31), a first motor winding (32) and a first half-bridge inverter module (33) which are connected in sequence; one end of the first relay (21) is connected to a charging port (11), and the other end is connected to the Boost module (31); the other end of the first half-bridge inverter module (33) is connected to a battery bus port (12).

5. The integrated Boost dual-motor controller according to claim 4, characterized in that: The controller also includes a second half-bridge inverter module (5); two inverter bridge heat dissipation slots (13) are symmetrically arranged in the housing (1); the first half-bridge inverter module (33) and the second half-bridge inverter module (5) are respectively fixed in the inverter bridge heat dissipation slots (13) on both sides; the inverter bridge heat dissipation slot (13) includes a plurality of interconnected heat dissipation cavities, and the heat dissipation cavities are connected to cooling channels.

6. The integrated Boost dual-motor controller according to claim 5, characterized in that: The cooling channel is provided on the back side of the housing (1), and comprises a liquid inlet, a liquid outlet, a first sub-channel and a second sub-channel. The first sub-channel and the second sub-channel are connected in parallel, one end of the first sub-channel and the second sub-channel are connected to the liquid inlet, and the other end of the first sub-channel is connected to the liquid outlet. The first sub-channel passes through the inverter bridge heat dissipation slot (13) below the first half-bridge inverter module (33), and the second sub-channel passes through the inverter bridge heat dissipation slot (13) below the second half-bridge inverter module (5).

7. The integrated Boost dual-motor controller according to claim 5, characterized in that: The shell (1) is also provided with a water channel cover plate on one side where the cooling channel is provided, and the water channel cover plate and the shell (1) are sealed by friction welding.

8. The integrated Boost dual-motor controller according to claim 4, characterized in that: The Boost module (31) comprises a current guide bar (311), a boost inductor (312) and a current sensor (313) connected in sequence, the current guide bar (311) is connected to a first relay (21), the current sensor (313) is connected to a first motor winding (32), an inductor heat dissipation cavity (14) is provided on the housing (1), and the Boost module (31) is fixed in the inductor heat dissipation cavity (14).

9. The integrated Boost dual-motor controller according to claim 8, characterized in that: The Boost module (31) is fixed in the inductor heat dissipation cavity (14) by epoxy potting.

10. The integrated Boost dual-motor controller according to claim 1, characterized in that: The controller also includes a four-phase busbar (6), the four-phase busbar (6) including a U copper busbar (61), a V copper busbar (62), a W copper busbar (63) and a boost copper busbar (64), three potting grooves (65) are provided on the plastic shell outside the four-phase busbar (6), an induction iron core (66) is provided in the potting groove (65), a Hall induction groove (67) is provided at the upper end of the potting groove (65), and an electronic chip for monitoring the current on the U copper busbar (61), the V copper busbar (62) and the W copper busbar (63) is embedded in the Hall induction groove (67).

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