Hall assembly, power module and motor controller

Abstract

The utility model discloses a Hall assembly, power module and motor controller relates to controller technical field, wherein the Hall assembly includes: support, Hall magnetic core and insulator, Hall magnetic core has first end and second end opposite to each other, first end is provided in the support, the second end protrudes out of the support and is provided with through groove, and the insulator is provided with through groove. The insulating part detachably wraps the second end. The power module comprises a mounting rack; the power module comprises a power module body and a terminal which are electrically connected, and the power module body is mounted on the mounting rack; the circuit board is arranged on one side, deviating from the mounting rack, of the power module body and is electrically connected with the power module body; and the Hall assembly is arranged on one side of the power module body and fixedly connected with the circuit board, and the terminal penetrates through the Hall assembly and extends towards the outer side of the mounting frame. According to the technical scheme provided by the utility model, the durability of the power module is improved.

Description

Technical Field

[0001] The utility model relates to the technical field of controllers, and particularly relates to a Hall component, a power module and a motor controller. Background Art

[0002] A Hall component is a current detection device based on the Hall effect principle, which is used to measure the magnitude of current in a circuit. The Hall effect is a physical phenomenon. When a magnetic field acts on the current passing through a Hall element, a voltage component perpendicular to the current direction and the magnetic field direction will be generated in the Hall element, that is, the Hall voltage. By measuring the magnitude of the Hall voltage, the current intensity passing through the Hall element can be calculated.

[0003] There is a current power module, which is composed of functional components such as a Hall component, a Hall PCB, a main circuit board, a Hall wire harness, and a power module. The Hall PCB is signal-connected to the main circuit board through the Hall wire harness, and each functional component is assembled in the motor controller by means of screw fastening and other methods.

[0004] During the use of such a power module, the local electric field intensity between the Hall component and the circuit board may exceed the electrical insulation strength of the air, causing the air to be ionized and generating electric sparks, resulting in easy damage to the power module. Summary of the Utility Model

[0005] The main purpose of the utility model is to propose a Hall component, a power module and a motor controller, aiming to improve the durability of the power module.

[0006] To achieve the above object, the Hall component proposed by the utility model includes:

[0007] A bracket;

[0008] A Hall magnetic core, which has opposite first and second ends. The first end is arranged inside the bracket, and the second end protrudes from the bracket and is provided with a through groove; and

[0009] An insulating member, detachably covering the second end.

[0010] In an embodiment, the insulating member is sleeved on the second end and detachably connected to the bracket.

[0011] In an embodiment, the insulating member includes:

[0012] An insulating body, sleeved on the second end; and

[0013] A buckle structure, arranged at one end of the insulating body facing the bracket and clamped with the bracket.

[0014] In an embodiment, the first end is injection-molded inside the bracket; and / or,

[0015] Three Hall magnetic cores are arranged at intervals on the bracket, and one insulating member is arranged corresponding to each Hall magnetic core.

[0016] In one embodiment, the bracket includes an integrally formed bracket body and a support column, the first end is disposed in the bracket body, one end of the support column is connected to the bracket body, and the other end of the support column extends in a direction away from the bracket body.

[0017] The utility model also provides a power module, comprising:

[0018] The Hall element mentioned above;

[0019] A power module, comprising an electrically connected power module body and a terminal, wherein the power module body is arranged at one side of the Hall component, and the terminal passes through the through slot and is provided with a notch to avoid the Hall magnetic core; and

[0020] A circuit board is arranged on one side of the power module body and is electrically connected to the power module body. The circuit board is fixed to the bracket.

[0021] In one embodiment, the power module further includes a mounting frame, which is disposed on a side of the power module body away from the circuit board, and the power module body, the bracket and the circuit board are all fixedly connected to the mounting frame.

[0022] In one embodiment, the mounting bracket is provided with a mounting groove, and the bracket is at least partially fixed in the mounting groove; and / or,

[0023] The bracket and the mounting frame are an integrated structure; and / or,

[0024] The mounting frame is provided with a heat dissipation water channel with an opening, the power module body is sealed at the periphery of the opening, and the notch is arranged close to the heat dissipation water channel.

[0025] In one embodiment, there is a gap between the terminal and the Hall component, and the gap is filled with adhesive.

[0026] The utility model also provides a motor controller, comprising:

[0027] The above-mentioned Hall element, or the above-mentioned power module.

[0028] In the technical solution of the present utility model, the Hall component includes a bracket, a Hall magnetic core, and an insulating member. The bracket wraps the first end of the Hall magnetic core, and the insulating member wraps the second end of the Hall magnetic core. The Hall magnetic core is completely wrapped by the bracket and the insulating member, which improves the electrical insulation strength around the Hall magnetic core. When the Hall component is assembled in the power module, it reduces the possibility that the local electric field strength between the Hall magnetic core and the circuit board exceeds the electrical insulation strength around the Hall magnetic core, avoiding the generation of electric sparks between the Hall magnetic core and the circuit board, thus making the power module not easily damaged, improving the durability of the power module, and also improving the safety of the power module. On the other hand, the terminals of the power module of the power module need to pass through the through groove. The insulating member is set in a detachable form, which facilitates the assembly of the Hall component and the power module of the power module, and improves the convenience of assembly and maintenance. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to more clearly illustrate the technical solutions in the embodiments of the present utility model or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only some embodiments of the present utility model. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on the structures shown in these drawings.

[0030] Figure 1 It is a schematic structural diagram of an embodiment of a power module provided by the present utility model;

[0031] Figure 2 It is an exploded view of an embodiment of a power module provided by the present utility model;

[0032] Figure 3 It is a schematic structural diagram of the mounting bracket of the power module provided by the present utility model;

[0033] Figure 4 It is a partial structural schematic diagram of an embodiment of a power module provided by the present utility model Figure 1 ;

[0034] Figure 5 It is a partial structural schematic diagram of an embodiment of a power module provided by the present utility model Figure 2 .

[0035] Explanation of the reference numerals in the drawings:

[0036] 100, Hall component; 110, Hall magnetic core; 111, through groove; 120, bracket; 121, bracket body; 122, support column; 130, insulating member; 131, insulating body; 132, snap structure;

[0037] 200, power module; 210, power module body; 220, terminal; 221, notch;

[0038] 300, circuit board;

[0039] 400, mounting bracket; 410, mounting groove; 420, heat dissipation water channel.

[0040] The realization, functional features and advantages of the purpose of the present utility model will be further described in conjunction with the embodiments and with reference to the accompanying drawings. Specific embodiments

[0041] Next, the technical solutions in the embodiments of the present utility model will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present utility model. Obviously, the described embodiments are only a part of the embodiments of the present utility model, rather than all of the embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present utility model.

[0042] It should be noted that if there are directional indications (such as up, down, left, right, front, back,...) involved in the embodiments of the present utility model, then such directional indications are only used to explain the relative positional relationship and movement conditions between components in a specific posture. If this specific posture changes, then such directional indications will also change accordingly.

[0043] In the present utility model, unless otherwise clearly defined and limited, terms such as "connection" and "fixation" should be understood in a broad sense. For example, "fixation" can be a fixed connection, a detachable connection, or integrated; "connection" can be a mechanical connection, an electrical connection, can be directly connected, or indirectly connected through an intermediate medium, and can be the communication inside two components or the interaction relationship between two components. Unless otherwise clearly limited, for those of ordinary skill in the art, the specific meanings of the above terms in the present utility model can be understood according to specific circumstances.

[0044] In addition, if there are descriptions such as "first" and "second" involved in the embodiments of the present utility model, then such "first" and "second" descriptions are only for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include at least one such feature. In addition, the meaning of "and / or" appearing throughout the text includes three parallel solutions. Taking "A and / or B" as an example, it includes solution A, or solution B, or the solution where A and B are satisfied simultaneously. In addition, the technical solutions between the various embodiments can be combined with each other, but it must be based on the fact that those of ordinary skill in the art can implement it. When the combination of technical solutions results in contradictions or cannot be implemented, it should be considered that such a combination of technical solutions does not exist and is not within the protection scope required by the present utility model.

[0045] The present utility model provides a Hall component.

[0046] Please refer to Figures 1 to 2 , Figure 1 which is a schematic structural diagram of an embodiment of a power module provided by the present utility model, Figure 2 and which is an exploded view of an embodiment of a power module provided by the present utility model;

[0047] In an embodiment of the present utility model, the Hall component 100 includes:

[0048] a bracket 120;

[0049] a Hall magnetic core 110 having opposite first and second ends, the first end being disposed within the bracket 120 and the second end protruding from the bracket 120 and having a through groove 111; and

[0050] an insulating member 130 detachably covering the second end.

[0051] The Hall component 100 in the technical solution of the present utility model includes a bracket 120, a Hall magnetic core 110 and an insulating member 130. The bracket 120 wraps the first end of the Hall magnetic core 110, and the insulating member 130 wraps the second end of the Hall magnetic core 110. The Hall magnetic core 110 is completely wrapped by the bracket 120 and the insulating member 130, improving the electrical insulation strength around the Hall magnetic core 110. When the Hall component 100 is assembled in the power module, the possibility that the local electric field strength between the Hall magnetic core 110 and the circuit board 300 exceeds the electrical insulation strength around the Hall magnetic core 110 is reduced, avoiding the generation of electric sparks between the Hall magnetic core 110 and the circuit board 300, so that the power module is not easily damaged, improving the durability of the power module and also improving the safety of the power module. On the other hand, the terminal 220 of the power module 200 of the power module needs to pass through the through groove 111. The insulating member 130 is provided in a detachable form, facilitating the assembly of the Hall component 100 with the power module 200 of the power module and improving the convenience of assembly and maintenance.

[0052] Among them, the insulating member 130 itself can achieve the insulation function by using insulating materials, pasting insulating paper, spraying insulating coatings, dispensing glue, etc.

[0053] In an embodiment, the insulating member 130 is sleeved on the second end and detachably connected to the bracket 120.

[0054] Refer to Figure 2 , Figure 4 and Figure 5, in the embodiment of the present utility model, the insulating member 130 is made of insulating materials such as rubber or plastic. The insulating member 130 can be sleeved on the part of the Hall magnetic core 110 exposed outside the bracket 120, so as to isolate the Hall magnetic core 110 from the circuit board 300. The insulating member 130 can be connected to the bracket 120 by means of snap connection or screw attachment, etc., to achieve the detachable function, so as to facilitate the disassembly of the Hall magnetic core 110 and the terminal 220, facilitate maintenance and replacement, and reduce the replacement cost.

[0055] In one embodiment, the insulating member 130 includes:

[0056] An insulating body 131, sleeved on the second end; and

[0057] A snap structure 132, provided at one end of the insulating body 131 facing the bracket 120, and snap-connected to the bracket 120.

[0058] Referring to Figure 2 、 Figure 4 and Figure 5 , in the embodiment of the present utility model, the insulating member 130 includes an insulating body 131 and a snap structure 132. Two snap structures 132 are provided on the insulating body 131. After the terminal 220 is assembled with the Hall magnetic core 110 from top to bottom, the insulating member 130 is snap-connected to the bracket 120 through the snap structure 132, which is convenient for assembly and disassembly; moreover, the bracket 120 and the insulating member 130 are clamped on the upper and lower sides of the terminal 220, improving the connection strength between the Hall component 100 and the terminal 220 and ensuring a firm connection between the Hall component 100 and the terminal 220.

[0059] In one embodiment, the first end is injection-molded into the bracket 120; and / or,

[0060] Three Hall magnetic cores 110 are provided on the bracket 120 at intervals, and one insulating member 130 is provided corresponding to each Hall magnetic core 110.

[0061] In the embodiment of the present utility model, the bracket 120 is made of injection-molded materials such as plastic or rubber, and the Hall magnetic core 110 is injection-molded in the bracket 120. The manufacturing process is simple, and the bracket 120 and the Hall magnetic core 110 are firmly fixed and not easy to separate.

[0062] Referring to Figure 2 , in the embodiment of the present utility model, the number of terminals 220 corresponds to the three-phase module, and the number of Hall magnetic cores 110 corresponds to the number of terminals 220. Three Hall magnetic cores 110 are injection-molded in the same bracket 120, reducing the number of parts, simplifying the assembly operation, and improving the integration of the Hall component 100.

[0063] In one embodiment, the bracket 120 includes an integrally formed bracket body 121 and a support column 122. One end of the support column 122 is disposed within the bracket body 121. One end of the support column 122 is connected to the bracket body 121, and the other end of the support column 122 extends away from the bracket body 121.

[0064] Referring to Figure 4 , in the embodiment of the present utility model, the bracket 120 includes a bracket body 121 and a support column 122. The support column 122 functions to support and connect the circuit board 300, ensuring that the circuit board 300 is firmly installed. The support column 122 and the circuit board 300 can be fixed in various ways such as gluing and screw fastening.

[0065] The present utility model also proposes a power module, including:

[0066] The above-mentioned Hall component 100;

[0067] A power module 200, including a power module body 210 and a terminal 220 that are electrically connected. The power module body 210 is disposed on one side of the Hall component 100. The terminal 220 passes through the through groove 111 and is provided with a notch 221 for avoiding the Hall magnetic core 110; and

[0068] A circuit board 300, disposed on one side of the power module body 210 and electrically connected to the power module body 210. The circuit board 300 is fixed to the bracket 120.

[0069] For the specific structure of the Hall component 100, refer to the above embodiment. Since this power module adopts all the technical solutions of the above embodiments, it at least has all the beneficial effects brought by the technical solutions of the above embodiments, which will not be elaborated here one by one. Combining Figure 1 , Figure 2 , Figure 4 and Figure 5, the power module includes a power module 200, a circuit board 300, and a Hall component 100. The terminal 220 of the power module 200 passes through the through slot 111 on the Hall core 110 for connecting to the three-phase module to achieve the Hall current detection function. The power module body 210 of the power module 200 is electrically connected to the circuit board 300. The terminal 220 of the power module 200 passes through the Hall component 100, and the circuit board 300 is fixedly connected to the bracket 120 of the Hall component 100, making the power module 200, the circuit board 300, and the Hall component 100 form an integral whole, improving the integration of the power module, facilitating assembly with other components, simplifying the assembly steps when assembling with other components, and reducing the assembly difficulty; on the other hand, reducing parts such as the Hall PCB and Hall wiring harness makes the number of components of the power module smaller, reducing the assembly difficulty and complexity of the power module itself, and also reducing the volume of the entire power module, improving the flexibility of power module assembly. In addition, compared with the existing solution of integrating the Hall component 100 and the three-phase module into one, the power module in this solution is decoupled from the three-phase module, so it can be applied to different motor interfaces and is convenient to be applied to different motors.

[0070] Among them, referring to Figure 2 and Figure 5 , a notch 221 corresponding to the Hall core 110 is provided on the terminal 220. When assembling the terminal 220 and the Hall component 100, the terminal 220 is assembled downward from above the through slot 111 so that the notch 221 is sleeved outside the Hall core 110, and then the terminal 220 can pass through the through slot 111. The assembly method is simple and easy to operate. The terminal 220 is sleeved outside the Hall core 110 through the notch 221, improving the position accuracy between the Hall core 110 and the terminal 220, and thus improving the assembly accuracy between the Hall component 100 and the power module 200.

[0071] In an embodiment, the power module further includes a mounting bracket 400. The mounting bracket 400 is provided on the side of the power module body 210 facing away from the circuit board 300, and the power module body 210, the bracket 120, and the circuit board 300 are all fixedly connected to the mounting bracket 400.

[0072] Combined with Figure 1 , Figure 2 , Figure 4 and Figure 5 , in the embodiment of the present utility model, the power module further includes a mounting bracket 400. The circuit board 300, the power module body 210, and the bracket 120 of the Hall component 100 are all fixed to the mounting bracket 400, and further making the mounting bracket 400, the power module 200, the circuit board 300, and the Hall component 100 form an integral whole, further improving the integration of the power module and facilitating the assembly of the whole with other components and simplifying the assembly steps.

[0073] In one embodiment, the mounting bracket 400 is provided with a mounting groove 410, and at least a part of the bracket 120 is fixed in the mounting groove 410; and / or,

[0074] The bracket 120 and the mounting bracket 400 are of an integral structure; and / or,

[0075] The mounting bracket 400 is provided with a heat dissipation water channel 420 with an opening, the power module body 210 is sealed at the periphery of the opening, and the notch 221 is arranged close to the heat dissipation water channel 420.

[0076] Referring to Figure 3 and Figure 4 , in the embodiment of the present utility model, the mounting bracket 400 is provided with a mounting groove 410, and a part of the bracket 120 is fixed in the mounting groove 410. On the one hand, the structure between the Hall component 100 and the mounting bracket 400 is made more compact. On the other hand, it is convenient to use the potting process to fix the Hall component 100 and the mounting bracket 400, thereby improving the connection strength between the Hall component 100 and the mounting bracket 400 and enhancing the heat transfer effect from the Hall component 100 to the mounting bracket 400. The bracket 120 can be fixed to the mounting bracket 400 by means of gluing, screw fastening, potting, etc. The mounting bracket 400 can be made of injection molding materials or metal materials, etc. When the Hall component 100 and the mounting bracket 400 are fixed in a detachable manner such as by screws, when a failure occurs among the Hall component 100, the power module 200 or the circuit board 300, it is not necessary to replace the mounting bracket 400 together, reducing the maintenance cost.

[0077] In the embodiment of the present utility model, the bracket 120 can be fixed to the mounting bracket 400 by potting, making the bracket 120 and the mounting bracket 400 an integral structure; when the mounting bracket 400 is made of plastic material, the bracket 120 and the mounting bracket 400 can also be integrally injection molded. By integrally arranging the bracket 120 and the mounting bracket 400, the connection strength between the Hall component 100 and the mounting bracket 400 can be improved, and the heat transfer effect from the Hall component 100 to the mounting bracket 400 can be enhanced

[0078] Referring to Figures 3 to 5In the embodiment of the utility model, the mounting frame 400 is provided with a heat dissipation channel 420. When the power module body 210 is fixed to the mounting frame 400, the opening of the heat dissipation channel 420 is closed, so that the coolant in the heat dissipation channel 420 directly exchanges heat with the power module body 210, thereby improving the heat dissipation effect of the power module body 210. In addition, the width of the terminal 220 at the notch 221 is relatively narrow, and the notch 221 is arranged close to the heat dissipation channel 420, thereby improving the heat dissipation effect of the heat dissipation channel 420 on the terminal 220 at the notch 221, and reducing the possibility of damage to the terminal 220. In particular, when the mounting frame 400 and the bracket 120 made of plastic material are integrally injection molded, or the bracket 120 is fixed in the mounting groove 410 of the mounting frame 400 by potting, the contact area is large, the heat conduction path is increased, and the heat dissipation effect of the heat dissipation channel 420 is further improved.

[0079] In an embodiment of the utility model, a capacitor is added to the power module to form an inverter module. The capacitor is arranged on a side of the mounting frame 400 away from the power module 200. The capacitor is fixed to the mounting frame 400 by potting. The Hall component 100 can be potted simultaneously with the capacitor to reduce the assembly steps of the inverter module.

[0080] The utility model also provides a motor controller, comprising:

[0081] The Hall element 100 mentioned above, or the power module mentioned above.

[0082] The specific structure of the Hall component 100 or the power module refers to the above-mentioned embodiments. Since the motor controller adopts all the technical solutions of all the above-mentioned embodiments, it has at least all the beneficial effects brought by the technical solutions of the above-mentioned embodiments, which will not be repeated here one by one. Among them, the use of the above-mentioned Hall component 100 reduces the possibility of electric sparks in the Hall component 100 and improves the durability and safety of the motor controller. The use of the above-mentioned power module simplifies the assembly steps of the motor controller and improves the assembly efficiency of the motor controller. The power module can be applied to different motor interfaces, which improves the scope of application of the motor controller, so that the motor controller can be applied to a variety of application scenarios such as a single motor powertrain, a distributed drive powertrain, a hybrid powertrain, and an all-in-one controller.

[0083] The above description is only an exemplary embodiment of the present invention, and does not limit the patent scope of the present invention. All equivalent structural changes made by using the contents of the present invention specification and drawings under the technical concept of the present invention, or directly / indirectly applied in other related technical fields are included in the patent protection scope of the present invention.

Claims

1. A Hall element, characterized in that: include: Bracket; A Hall magnetic core, the Hall magnetic core having a first end and a second end opposite to each other, the first end being arranged in the bracket, and the second end protruding from the bracket and having a through groove; as well as An insulating member detachably covers the second end.

2. The Hall assembly according to claim 1, characterized in that: The insulating member is sleeved on the second end and is detachably connected to the bracket.

3. The Hall assembly according to claim 2, characterized in that: The insulating member comprises: an insulating body, sleeved on the second end; and The buckle structure is arranged at one end of the insulating body facing the bracket and is buckled with the bracket.

4. The Hall assembly according to claim 1, characterized in that: The first end is injection molded into the bracket; and / or, Three Hall magnetic cores are arranged at intervals on the bracket, and one insulating member is arranged corresponding to each Hall magnetic core.

5. The Hall assembly according to claim 1, characterized in that: The bracket includes an integrally formed bracket body and a support column, the first end is arranged in the bracket body, one end of the support column is connected to the bracket body, and the other end of the support column extends in a direction away from the bracket body.

6. A power module, characterized in that: include: The Hall assembly according to any one of claims 1 to 5; A power module, comprising an electrically connected power module body and a terminal, wherein the power module body is arranged at one side of the Hall component, and the terminal passes through the through slot and is provided with a notch to avoid the Hall magnetic core; and A circuit board is arranged on one side of the power module body and is electrically connected to the power module body. The circuit board is fixed to the bracket.

7. The power module according to claim 6, characterized in that: The power module also includes a mounting frame, which is arranged on a side of the power module body away from the circuit board, and the power module body, the bracket and the circuit board are all fixedly connected to the mounting frame.

8. The power module according to claim 7, characterized in that: The mounting frame is provided with a mounting groove, and the bracket is at least partially fixed in the mounting groove; and / or, The bracket and the mounting frame are an integrated structure; and / or, The mounting frame is provided with a heat dissipation water channel with an opening, the power module body is sealed at the periphery of the opening, and the notch is arranged close to the heat dissipation water channel.

9. The power module according to claim 6, characterized in that: There is a gap between the terminal and the Hall component, and the gap is filled with adhesive.

10. A motor controller, characterized in that: include: A Hall assembly as claimed in any one of claims 1 to 5, or a power module as claimed in any one of claims 6 to 9.

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