New energy automobile multifunctional power converter

Abstract

The utility model relates to a multifunctional power converter for a new energy automobile. The multifunctional power converter comprises a converter shell assembly, an inversion converter, a power supply system and a large box cover, the large box cover is arranged on the converter shell assembly to form a closed cavity; the inversion converter and the power supply system are integrated on the two sides of the interior of a cavity of the converter shell assembly respectively. The converter shell assembly comprises a cooling assembly, and the cooling assembly is arranged in the converter shell assembly and on the outer surface of the converter shell assembly. Compared with the prior art, the inverter converter and the power supply system are integrated in the cavity on the same side of the converter shell assembly, so that the inverter converter and the power supply system can share part of electrical functions, and electric energy transmission and communication can be carried out; the cooling assembly is arranged inside and on the outer surface of the converter shell assembly, and the cooling effect is good; and a tandem water channel structure is adopted, that is, cooling liquid sequentially flows through the cooling water channels of the power supply system and the inversion converter to cool the power supply system and the inversion converter, and the cooling effect is good.

Description

Technical Field

[0001] The utility model relates to the field of electric drive of new energy vehicles, in particular to a multi-functional power converter for new energy vehicles. Background Art

[0002] The existing multi-functional power converters for new energy vehicles have the following problems:

[0003] Although the high-voltage junction box, inverter converter, on-vehicle charger and DC / DC converter have been integrated into one controller, the integration degree is still poor, and the components are not integrated with each other. Moreover, these components are still installed in the shell as independent packaged devices, rather than directly packaged in the shell of the whole machine. Therefore, the number of parts will increase, and the volume of the whole power converter will increase. Since the inverter converter, on-vehicle charger and DC / DC converter inside the power converter all need to dissipate heat, in some existing technical solutions, the inverter converter, on-vehicle charger and DC / DC converter are respectively installed on the upper and lower surfaces of the heat dissipation structure and share a water channel for heat dissipation. The heat dissipation effect of this heat dissipation solution is poor and it is difficult to meet the actual use requirements.

[0004] After retrieval, the authorized publication number CN20782739U discloses an integrated motor controller for electric vehicles, which specifically discloses: it includes a motor controller, a DC / DC converter and an on-vehicle charger. The motor controller, DC / DC converter and on-vehicle charger are integrally packaged in a shell. The shell is provided with a heat dissipation bottom plate and an interface for docking with the vehicle wiring harness; the input ends of the motor controller, the DC / DC converter and the output end of the on-vehicle charger share a set of positive and negative interfaces; the motor controller is provided with an interface for connecting to the motor, the DC / DC converter is provided with an interface for charging the low-voltage battery, and the on-vehicle charger is provided with an interface for connecting to the on-vehicle charging port. However, the cooling water channel of this existing technology is only located at the bottom of the shell, and the heat dissipation effect is not good.

[0005] The authorized publication number CN202782739U discloses an integrated motor controller for electric vehicles, which specifically discloses: including a motor controller, a DC / DC converter and an on-vehicle charger. The motor controller, DC / DC converter and on-vehicle charger are integrally packaged in a shell. The shell is provided with a heat dissipation bottom plate and an interface for docking with the vehicle wiring harness; the input ends of the motor controller, the DC / DC converter and the output end of the on-vehicle charger share a set of positive and negative interfaces; the motor controller is provided with an interface for connecting to the motor, the DC / DC converter is provided with an interface for charging the low-voltage battery, and the on-vehicle charger is provided with an interface for connecting to the on-vehicle charging port. However, in this existing technology, the on-vehicle charger and the DC / DC converter are located at different positions and are cooled through different cooling water channels, and the volume is large.

[0006] In summary, how to design a power converter with high component integration and good heat dissipation effect is a technical problem to be solved. Summary of the Invention

[0007] The purpose of the present utility model is to provide a multifunctional power converter for new energy vehicles to overcome the defect of poor cooling effect in the above-mentioned existing technologies.

[0008] The purpose of the present utility model can be achieved by the following technical solutions:

[0009] According to one aspect of the present utility model, there is provided a multifunctional power converter for new energy vehicles, including a converter housing assembly, an inverter converter, a power supply replenishment system, and a large box cover; the large box cover is installed on the converter housing assembly to form a closed cavity; the inverter converter and the power supply replenishment system are integrated inside the cavity of the converter housing assembly; the converter housing assembly includes a cooling component, and the cooling component is arranged inside and on the outer surface of the converter housing assembly.

[0010] As a preferred technical solution, the cooling component includes a water inlet pipe, a cooling water channel for the power supply replenishment system, a transfer water channel, a water channel cover plate, and a cooling water tank for the inverter converter. The water inlet pipe is connected to the outer surface of the converter housing assembly from the outside; the transfer water channel is arranged on the outer surface of the converter housing assembly, one end is connected to the water inlet pipe, and the inside is communicated with the cooling water channel for the power supply replenishment system and the cooling water tank for the inverter converter; the water channel cover plate covers the transfer water channel.

[0011] As a preferred technical solution, the converter housing assembly further includes an inverter converter cavity and a power supply replenishment system cavity, and the inverter converter and the power supply replenishment system are respectively installed in the inverter converter cavity and the power supply replenishment system cavity.

[0012] As a preferred technical solution, the cooling water channel for the power supply replenishment system is in a "Π" shape and is located inside the power supply replenishment system cavity; the cooling water tank for the inverter converter is located inside the inverter converter cavity.

[0013] As a preferred technical solution, the water channel cover plate is welded to the transfer water channel by friction stir welding; the inverter converter is installed inside the inverter converter cavity by screws; the power supply replenishment system is encapsulated inside the power supply replenishment system cavity by potting glue.

[0014] As a preferred technical solution, the inverter converter includes a DC filter, a DC support capacitor, an IGBT, a control board, a three-phase output bracket, a current sensor, and a resolver harness. The DC filter, the DC support capacitor, the IGBT, the three-phase output bracket, and the current sensor are installed in sequence; the control board is installed on the surfaces of the IGBT and the three-phase output bracket; the resolver harness is installed on the surface of the control board.

[0015] As a preferred technical solution, the DC support capacitor includes a DC support capacitor body, a DC support capacitor output terminal, and a DC support capacitor output terminal support seat. The DC support capacitor output terminal is led out from the DC support capacitor body, and the DC support capacitor output terminal support seat and the DC support capacitor body are of an integrated structure.

[0016] As a preferred technical solution, a plurality of round nuts are embedded inside the DC support capacitor output terminal support seat, and the round nuts correspond to the DC support capacitor output terminals one by one.

[0017] As a preferred technical solution, the power converter further includes a small box cover. A square through hole is provided on the large box cover, the small box cover covers the square through hole, and the small box cover and the large box cover are sealed by a sealing ring.

[0018] As a preferred technical solution, the large box cover is fixed to the converter housing assembly by screws.

[0019] Compared with the prior art, the present utility model has the following beneficial effects:

[0020] 1) The inverter converter and the power supply replenishment system of the present utility model are integrated inside the same side cavity of the converter housing assembly, which is beneficial to realizing the sharing of some electrical functions between the motor controller and the power supply replenishment system, and facilitating the power transmission and communication between the two; the cooling assembly is arranged inside and on the outer surface of the converter housing assembly, and the cooling effect is good;

[0021] 2) The present utility model adopts a series water channel structure, that is, the coolant flows through the cooling water channels of the power supply replenishment system and the inverter converter in sequence to dissipate heat from both of them, and the heat dissipation effect is good;

[0022] 3) The housing and the cooling water channel of the power supply replenishment system of the present utility model are directly integrated on the converter housing assembly, and the power supply replenishment system is directly potted inside the converter housing assembly, eliminating the housing of the power supply replenishment system itself, improving the integration degree of the system, and making the whole machine smaller in volume;

[0023] 4) The DC support capacitor output terminal bracket and the DC support capacitor of the present utility model are integrated into one body, which can save the number of parts, reduce the part cost, and simplify the assembly process. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a schematic diagram of the overall structure of a multifunctional power converter for a new energy vehicle according to the present utility model;

[0025] Figure 2 It is a schematic diagram of the internal structure of the converter housing assembly according to the present utility model;

[0026] Figure 3 This is a schematic diagram of the outer surface structure of the converter housing assembly of the utility model;

[0027] Figure 4 This is a schematic diagram of the overall structure of the inverter converter of the utility model;

[0028] Figure 5 This is a schematic diagram of the overall structure of the DC support capacitor of the utility model;

[0029] The numbers in the figure show:

[0030] 1. Converter housing assembly, 10. Inverter converter cavity, 11. Power supply system cavity, 12. Water inlet pipe, 13. Power supply system cooling water channel, 14. Transfer water channel, 15. Water channel cover, 16. Inverter converter cooling water tank, 2. Inverter converter, 20. DC filter, 21. DC support capacitor, 210. DC support capacitor body, 211. DC support capacitor output terminal, 212. DC support capacitor output terminal support, 22. IGBT, 23. Control board, 24. Three-phase output bracket, 25. Current sensor, 26. Rotary transformer wiring harness, 3. Power supply system, 4. Large box cover, 5. Small box cover. DETAILED DESCRIPTION

[0031] The following will be combined with the drawings in the embodiments of the utility model to clearly and completely describe the technical solutions in the embodiments of the utility model. Obviously, the described embodiments are part of the embodiments of the utility model, not all of them. Based on the embodiments in the utility model, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the utility model.

[0032] The utility model provides a multifunctional power converter for new energy vehicles, comprising a converter housing assembly 1, an inverter converter 2, a power supply system 3, a large box cover 4 and a small box cover 5.

[0033] The converter housing assembly 1 includes an inverter converter cavity 10, a power supply system cavity 11 and a cooling component.

[0034] The inverter converter 2 is installed inside the inverter converter cavity 10 by screws, and the power supply system 3 is encapsulated inside the power supply system cavity 11 by potting glue, eliminating the housing of the power supply system 3. The power supply system 3 can also be designed as an independent packaged device including a cooling water channel, which is directly installed on the converter housing assembly 1.

[0035] The cooling assembly includes a water inlet pipe 12, a power supply system cooling water channel 13, a transfer water channel 14, a water channel cover plate 15, and an inverter converter cooling water tank 16. The water inlet pipe 12 is connected to the outer surface of the converter housing assembly 1 from the outside. The transfer water channel 14 is arranged on the outer surface of the converter housing assembly 1, with one end connected to the water inlet pipe 12, spanning across the outer surfaces of the inverter converter cavity 10 and the power supply system cavity 11, and internally communicating with the power supply system cooling water channel 13 and the inverter converter cooling water tank 16. The power supply system cooling water channel 13 is in a "Π" shape and is located within the power supply system cavity 11; the inverter converter cooling water tank 16 is located within the inverter converter cavity 10. The water channel cover plate 15 covers the transfer water channel 14 and is welded to the transfer water channel 14 by friction stir welding. The coolant flows through the water inlet pipe 12, the power supply system cooling water channel 13, the transfer water channel 14, the water channel cover plate 15, and the inverter converter cooling water tank 16 in sequence.

[0036] The inverter converter 2 includes a DC filter 20, a DC support capacitor 21, an IGBT 22 (Insulated Gate Bipolar Transistor), a control board 23, a three-phase output bracket 24, a current sensor 25, and a resolver harness 26. The DC filter 20, the DC support capacitor 21, the IGBT 22, the three-phase output bracket 24, and the current sensor 25 are sequentially installed and arranged inside the inverter converter cavity 10; the control board 23 is installed on the upper surfaces of the IGBT 22 and the three-phase output bracket 24; the resolver harness 26 is installed on the upper surface of the control board 23.

[0037] The DC support capacitor 21 includes a DC support capacitor body 210, a DC support capacitor output terminal 211, and a DC support capacitor output terminal support 212. The DC support capacitor output terminal 211 extends from the DC support capacitor body 210, and the DC support capacitor output terminal support 212 is an integral structure with the DC support capacitor body 210. The DC support capacitor output terminal support 212 can also be designed as a separate part and fixed inside the inverter converter cavity 10 of the converter housing assembly 1. A plurality of round nuts are embedded inside the DC support capacitor output terminal support 212, optionally 6 round nuts, and each round nut is located directly below the corresponding DC support capacitor output terminal 211.

[0038] The large box cover 4 is fixed above the converter housing assembly 1 by screws, and the two are sealed with sealant to form a closed cavity.

[0039] The large box cover 4 has a square through-hole, and the small box cover 5 is fixed above the large box cover 4 to cover this square through-hole. The small box cover 5 and the large box cover 4 are sealed with a customized sealing ring.

[0040] In the present utility model, the inverter converter 2 and the power supply replenishment system 3 (i.e., an integrated two-in-one system of an on-vehicle charger and a DC / DC converter) are integrated inside the same-side cavity of the converter housing assembly 1, which is conducive to realizing the sharing of some electrical functions between the inverter converter 2 and the power supply replenishment system 3, and facilitating the power transmission and communication between the two. In the present utility model, the power supply replenishment system cavity 11 and the power supply replenishment system cooling water channel 13 are directly integrated on the converter housing assembly 1, saving the housing of the power supply replenishment system 3 itself.

[0041] The installation process of each part of the present utility model is as follows:

[0042] 1) Weld the water channel cover plate 15 on the converter housing assembly 1;

[0043] 2) Crimp the water inlet pipe 12 on the converter housing assembly 1;

[0044] 3) Pot the power supply replenishment system 3 in the power supply replenishment system cavity 11 inside the converter housing assembly 1;

[0045] 4) Install the DC filter 20 and the DC support capacitor 21 in sequence in the inverter converter cavity 10 inside the converter housing assembly 1, and connect the input terminal of the DC support capacitor 21 and the output terminal of the DC filter 20 with screws;

[0046] 5) Install the resolver harness 26 inside the converter housing assembly 1;

[0047] 6) Assemble the IGBT 22, the current sensor 25, and the three-phase output bracket 24 together;

[0048] 7) Install a sealing ring inside the converter housing assembly 1, and install the IGBT 22 on it. Connect the output terminal of the IGBT 22 and the output terminal of the DC support capacitor 21 with screws;

[0049] 8) Conduct a water channel airtightness test. After passing the test, proceed to the next assembly step;

[0050] 9) Install the control board 23 above the IGBT 22 and weld them together;

[0051] 10) Plug one end of the resolver harness 26 into the control board 23;

[0052] 11) Conduct an insulation withstand voltage test for the whole machine;

[0053] 12) Apply sealant to the bottom of the large box cover 4 and dry it;

[0054] 13) Fix the large box cover 4 on the converter housing assembly 1;

[0055] 14) Install a sealing ring above the large box cover 4 and fix the small box cover 5 on it;

[0056] 15) Conduct an airtight test on the whole machine. If the test is qualified, the assembly is completed.

[0057] As described above, it is only the specific implementation manner of the present utility model, but the protection scope of the present utility model is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present utility model can easily think of various equivalent modifications or substitutions, and these modifications or substitutions should be covered within the protection scope of the present utility model. Therefore, the protection scope of the present utility model shall be subject to the protection scope of the claims.

Claims

1. A multifunctional power converter for new energy vehicles, characterized in that: The invention comprises a converter housing assembly (1), an inverter converter (2), a power supply system (3) and a large box cover (4); the large box cover (4) is mounted on the converter housing assembly (1) to form a closed cavity; the inverter converter (2) and the power supply system (3) are integrated inside the cavity of the converter housing assembly (1); the converter housing assembly (1) comprises a cooling component, which is arranged inside and on the outer surface of the converter housing assembly (1).

2. A multifunctional power converter for new energy vehicles according to claim 1, characterized in that: The cooling assembly comprises a water inlet pipe (12), a power supply system cooling water channel (13), a transfer water channel (14), a water channel cover plate (15) and an inverter converter cooling water tank (16); the water inlet pipe (12) is connected to the outer surface of the converter housing assembly (1) from the outside; the transfer water channel (14) is arranged on the outer surface of the converter housing assembly (1), one end of which is connected to the water inlet pipe (12) and the interior of which is connected to the power supply system cooling water channel (13) and the inverter converter cooling water tank (16); the water channel cover plate (15) is covered on the transfer water channel (14).

3. A multifunctional power converter for new energy vehicles according to claim 2, characterized in that: The converter housing assembly (1) further comprises an inverter converter cavity (10) and a power supply system cavity (11), and the inverter converter (2) and the power supply system (3) are respectively installed in the inverter converter cavity (10) and the power supply system cavity (11).

4. A multifunctional power converter for new energy vehicles according to claim 3, characterized in that: The power supply system cooling water channel (13) is of "Π" type and is located in the power supply system cavity (11); the inverter converter cooling water tank (16) is located in the inverter converter cavity (10).

5. A multifunctional power converter for new energy vehicles according to claim 3, characterized in that: The water channel cover plate (15) is welded to the transfer water channel (14) by means of stir friction welding; the inverter converter (2) is installed inside the inverter converter cavity (10) by means of screws; and the power supply system (3) is encapsulated inside the power supply system cavity (11) by means of potting glue.

6. A multifunctional power converter for new energy vehicles according to claim 1, characterized in that: The inverter converter (2) comprises a DC filter (20), a DC support capacitor (21), an IGBT (22), a control board (23), a three-phase output bracket (24), a current sensor (25) and a resolver harness (26); the DC filter (20), the DC support capacitor (21), the IGBT (22), the three-phase output bracket (24) and the current sensor (25) are installed in sequence; the control board (23) is installed on the surface of the IGBT (22) and the three-phase output bracket (24); and the resolver harness (26) is installed on the surface of the control board (23).

7. A multifunctional power converter for new energy vehicles according to claim 6, characterized in that: The DC support capacitor (21) comprises a DC support capacitor body (210), a DC support capacitor output terminal (211) and a DC support capacitor output terminal support (212); the DC support capacitor output terminal (211) is led out from the DC support capacitor body (210); and the DC support capacitor output terminal support (212) and the DC support capacitor body (210) are an integrated structure.

8. A multifunctional power converter for new energy vehicles according to claim 7, characterized in that: A plurality of round nuts are embedded inside the DC support capacitor output terminal support (212), and the round nuts correspond one-to-one to the DC support capacitor output terminals (211).

9. The multifunctional power converter for new energy vehicles according to claim 1, characterized in that: The power converter further comprises a small box cover (5), the large box cover (4) is provided with a square through hole, the small box cover (5) covers the square through hole, and the small box cover (5) and the large box cover (4) are sealed by a sealing ring.

10. The multifunctional power converter for new energy vehicles according to claim 1, characterized in that: The large box cover (4) is fixed to the converter housing assembly (1) by means of screws.

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