Controller integrated structure of three-in-one integrated shell

Abstract

The utility model relates to the field of controllers of electric automobiles, and discloses a controller integrated structure of a three-in-one integrated shell. The controller integrated structure comprises a shell, an inversion brick module and a filtering assembly, the shell comprises a second open slot, a third open slot and a first open slot which are respectively used for mounting a motor, a speed reducer and a controller; a first counter bore and a second counter bore are formed in the first open slot, the depth of the first counter bore is larger than that of the second counter bore, the inverter brick module is arranged in the first counter bore, and the filtering assembly is arranged in the second counter bore. According to the controller integrated structure, the shell with the three opening grooves is arranged and used for installing the motor, the speed reducer and the controller, integration of the three-in-one shell is achieved, the weight is reduced, and the shell strength is improved; and the inverter brick module is arranged to deeply integrate components such as a water channel substrate, and the filtering assembly is arranged to deeply integrate components such as a filtering plate, so that the heat dissipation efficiency and the integration degree are further improved, and the reliability of the product is ensured.

Description

Technical Field

[0001] The utility model relates to the field of controllers for electric vehicles, and particularly to a controller integration structure with a three-in-one integrated housing. Background Art

[0002] With the continuous development of the new energy vehicle industry, the types of new energy electric vehicles are increasing, with various functions. However, the structural design and physical integration of many new energy vehicle models are still relatively simple. The drive system of traditional new energy vehicles is a split drive, where the electric drive controller, motor, and reducer are designed with separate housings and assembled separately; the electric drive controller assembles the heat dissipation module and the drive control board separately, and finally assembles and integrates them as a whole; this makes the overall weight of the above drive system too large, the operating temperature too high, which is not conducive to assembly production, the assembly process is complex, the integration level is low, the dimensional chain between parts is high, and it affects various performance such as the NVH performance and heat dissipation of the electric drive. Content of the Utility Model

[0003] In order to overcome the above technical problems, the utility model provides a controller integration structure with a three-in-one integrated housing. The controller integration structure realizes the integration of the motor housing, reducer housing, and controller housing by setting a housing with three opening slots for installing the motor, reducer, and controller, reducing the weight and improving the housing strength; and sets the inverter brick module to deeply integrate components such as IGBT module, PCB board, water channel substrate, and thin film capacitor, and sets the filtering component to deeply integrate components such as filtering board and various capacitors, further improving the heat dissipation efficiency and integration level, and ensuring the reliability of the product.

[0004] In order to achieve the above object, on the one hand, the utility model provides a controller integration structure with a three-in-one integrated housing, and the controller integration structure includes:

[0005] A housing, the housing includes:

[0006] A first opening slot for installing a controller;

[0007] A second opening slot for installing a motor;

[0008] A third opening slot for installing a reducer;

[0009] A first counterbore and a second counterbore are provided in the first opening slot, and the depth of the first counterbore is greater than the depth of the second counterbore;

[0010] A filtering component is arranged in the second counterbore;

[0011] An inverter brick module is arranged in the first counterbore.

[0012] Preferably, the inverter brick module further includes:

[0013] A thin-film capacitor, the bottom of the thin-film capacitor being closely attached to the bottom of the first counterbore;

[0014] A water channel substrate, the bottom of the water channel substrate being disposed on the top of the thin-film capacitor;

[0015] An IGBT module, the IGBT module being fixedly disposed on the top of the water channel substrate;

[0016] An IGBT sealing ring, being hermetically disposed between the IGBT module and the water channel substrate;

[0017] A three-phase current sensor, being closely attached to the top of the water channel substrate;

[0018] A PCB board, being disposed above the IGBT module and the three-phase current sensor;

[0019] A chip protection clip, the chip protection clip being fixedly disposed on the PCB board.

[0020] Preferably, the filtering component includes:

[0021] A positive copper busbar, being disposed at one end of one side of the filtering component;

[0022] A negative copper busbar, being disposed at one end of the other side of the filtering component;

[0023] A DC input terminal and a DC output terminal, being electrically connected to the inverter brick module;

[0024] A filtering board, being electrically connected to the DC input terminal and the DC output terminal, and being disposed between the DC input terminal and the DC output terminal;

[0025] A filtering copper busbar heat dissipation surface, the copper busbar heat dissipation surface being closely attached to the bottom surface of the second counterbore.

[0026] Preferably, the water channel substrate and the thin-film capacitor are integrally formed;

[0027] The water channel substrate and the first counterbore are end-face sealed, and a bowl-shaped hole is provided on the side surface of the water channel substrate, and the bowl-shaped hole is matched with an external bowl-shaped hole plug to seal the first water channel in the water channel substrate.

[0028] Preferably, the three-phase current sensor includes:

[0029] Three-phase copper busbars;

[0030] A wound iron core, the wound iron core and the three-phase copper busbars being integrally injection molded;

[0031] The filtering magnetic ring is sealed by dispensing and capping with the injection molded housing of the three-phase copper busbar;

[0032] The heat dissipation surface of the three-phase copper busbar is closely attached to the top of the water channel substrate.

[0033] Preferably, the first opening groove is arranged at the top of the housing;

[0034] The second opening groove is arranged on one side of the housing and cooperates with the rear cover outside the motor to seal the whole motor;

[0035] The third opening groove is arranged on the other side of the housing adjacent to the second opening groove and cooperates with the rear cover outside the reducer to seal the whole reducer.

[0036] Preferably, the housing includes a second water channel, and the second water channel is arranged inside the housing closely attached to the first opening groove and the second opening groove.

[0037] Preferably, the water inlet and outlet of the first water channel are correspondingly connected to the second water channel.

[0038] Preferably, the controller integrated structure further includes a sealing cover plate, which is fixedly arranged on the first opening groove;

[0039] A retaining wall is arranged between the first counterbore and the second counterbore.

[0040] Preferably, the sealing cover plate further includes an observation port and a small cover plate. The observation port is arranged at one end of the sealing cover plate close to the second counterbore, and the small cover plate is hermetically arranged on the observation port.

[0041] Through the above technical solutions, the controller integrated structure realizes the integration of the motor housing, the reducer housing and the controller housing by arranging a housing with three opening grooves for installing the motor, the reducer and the controller, which reduces the weight, reduces a large number of connecting parts, makes the housing structure more compact, improves the housing strength, improves the NVH performance and reduces the cost; and the inverter brick module deeply integrates components such as IGBT module, PCB board, water channel substrate, thin film capacitor, etc., and the filtering component deeply integrates components such as filtering board and various capacitors, which further improves the heat dissipation efficiency and integration degree, reduces the material cost, greatly reduces the assembly complexity, improves the assembly fault tolerance rate and space utilization rate, and ensures the reliability of the product. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1 is a schematic structural diagram of a controller integrated structure of a three-in-one integrated housing according to an embodiment of the present invention;

[0043] Figure 2 Schematic diagram of the structure of the housing of the controller integration structure of a three-in-one integrated housing according to an embodiment of the present invention;

[0044] Figure 3 Schematic diagram of the structure of the filter component of the controller integration structure of a three-in-one integrated housing according to an embodiment of the present invention;

[0045] Figure 4 Schematic diagram of the structure of the three-phase current sensor of the controller integration structure of a three-in-one integrated housing according to an embodiment of the present invention.

[0046] Description of reference numerals

[0047] 1. Housing 2. Inverter brick module

[0048] 3. Filter component 4. Sealing cover plate

[0049] 11. First opening groove 12. Third opening groove

[0050] 13. Second opening groove 21. Water channel substrate

[0051] 22. IGBT module 23. IGBT sealing ring

[0052] 24. Three-phase current sensor 25. PCB board

[0053] 26. Chip protection clip 27. Thin film capacitor

[0054] 31. Positive copper busbar 32. Negative copper busbar

[0055] 33. Filter copper busbar heat dissipation surface 41. Observation port

[0056] 42. Small cover plate 111. First counterbore

[0057] 112. Second counterbore 113. Retaining wall

[0058] 241. Three-phase copper busbar 242. Wound iron core

[0059] 243. Filter magnetic ring 244. Three-phase copper busbar heat dissipation surface Detailed implementation manners

[0060] The following will describe in detail the specific implementation manners of the embodiments of the present invention with reference to the accompanying drawings. It should be understood that the specific implementation manners described herein are only used to illustrate and explain the embodiments of the present invention, and are not used to limit the embodiments of the present invention.

[0061] As Figure 1The figure shows a schematic structural diagram of a controller integration structure of a three-in-one integrated housing according to an embodiment of the present utility model; as Figure 2 The figure shows a schematic structural diagram of the housing of a controller integration structure of a three-in-one integrated housing according to an embodiment of the present utility model; in Figure 1 and Figure 2 As shown, the controller integration structure includes a housing 1, an inverter brick module 2, and a filtering component 3; specifically, the housing 1 includes a second opening groove 13, a third opening groove 12, and a first opening groove 11, which are respectively used for installing a motor, a reducer, and a controller; a first counterbore 111 and a second counterbore 112 may be provided on the first opening groove 11, the depth of the first counterbore 111 is greater than the depth of the second counterbore 112, the inverter brick module 2 may be disposed in the first counterbore 111 of the first opening groove 11, and the filtering component 3 may be disposed in the second counterbore 112 of the first opening groove 11. The first counterbore has a deeper depth than the second counterbore, so that more components can be placed. At the same time, the second counterbore is close to the third opening groove and can be coupled to the third opening groove to improve the space utilization rate.

[0062] Through the above technical solution, the controller integration structure realizes the integration of the motor housing, the reducer housing, and the controller housing by providing a housing with three opening grooves for installing the motor, the reducer, and the controller, reducing the weight, reducing a large number of connecting parts, making the housing structure more compact, improving the housing strength, improving the NVH performance, and reducing the cost; and the inverter brick module deeply integrates components such as IGBT modules, PCB boards, water channel substrates, and thin film capacitors, and the filtering component deeply integrates components such as filtering boards and various capacitors, further improving the heat dissipation efficiency and integration degree, reducing the material cost, greatly reducing the assembly complexity, improving the assembly fault tolerance rate and space utilization rate, and ensuring the reliability of the product.

[0063] In Figure 1Among them, to meet the assembly requirements and improve the assembly efficiency. In an embodiment of the present utility model, the inverter brick module 2 further includes a film capacitor 27, a water channel substrate 21, an IGBT module 22, an IGBT sealing ring 23, a three-phase current sensor 24, a chip protection clip 26, and a PCB board 25. The bottom of the film capacitor 27 can be closely arranged on the bottom of the first counterbore 111, the bottom of the water channel substrate 21 can be arranged on the top of the film capacitor 27, and the IGBT module 22 is fixedly arranged on the top of the water channel substrate 21; the IGBT sealing ring 23 can be hermetically arranged between the IGBT module 22 and the water channel substrate 21 to prevent the coolant in the water channel from flowing out; the three-phase current sensor 24 can be closely arranged on the top of the water channel substrate 21 and is electrically connected to the IGBT module 22; the PCB board 25 can be arranged above the IGBT module 22 and the three-phase current sensor 24 and is electrically connected to the IGBT module 22; the chip protection clip 26 can be fixedly arranged on the PCB board 25 to protect the PCB board 25; the inverter brick module 2 is deeply integrated according to the arrangement mode of the above components, greatly improving the heat dissipation efficiency and operation efficiency and ensuring the stable operation of the working conditions.

[0064] As Figure 3 shown is a schematic structural diagram of a filtering component of a controller integration structure of a three-in-one integrated housing according to an embodiment of the present utility model; in Figure 3 Among them, to meet the assembly requirements and improve the assembly efficiency. In an embodiment of the present utility model, the filtering component 3 may include a positive copper bar 31, a negative copper bar 32, a DC input terminal (not marked in the figure), a DC output terminal (not marked in the figure), a filtering board (not marked in the figure), and a filtering copper bar heat dissipation surface 33. The positive copper bar 31 can be arranged at one end on one side of the filtering component 3; the negative copper bar 32 can be arranged at one end on the other side of the filtering component 3; the DC input terminal and the DC output terminal can be electrically connected to the inverter brick module 2; the filtering board can be electrically connected to the DC input terminal and the DC output terminal and is arranged between the DC input terminal and the DC output terminal; the copper bar heat dissipation surface 33 can be closely attached to the bottom surface of the second counterbore 112. The DC input terminal can integrate a nanocrystalline magnetic ring, the DC output terminal can integrate a ferrite magnetic ring, and the filtering board can integrate a plurality of X capacitors and a plurality of Y capacitors. This filtering structure has a high integration degree and can meet different EMC level requirements.

[0065] In Figure 1In order to ensure the demolding reliability of the water channel substrate 21 and the thin film capacitor 27 and meet the sealing effect of the water channel. In an embodiment of the present invention, the water channel substrate 21 and the thin film capacitor 27 can be integrally formed; the water channel substrate 21 can be end-sealed with the first counterbore 111, and a bowl-shaped hole (not marked in the figure) is provided on the side of the water channel substrate 21, and the bowl-shaped hole cooperates with an external bowl-shaped hole plug to seal the first water channel (not marked in the figure) in the water channel substrate 21.

[0066] As Figure 4 shown is a schematic structural diagram of a three-phase current sensor of a controller integration structure of a three-in-one integrated housing according to an embodiment of the present invention; in Figure 4 In consideration of the connection method of the three-phase current sensor 24 to meet current sampling. In an embodiment of the present invention, the three-phase current sensor 24 includes three-phase copper bars 241, a wound iron core 242, a filtering magnetic ring 243, and a three-phase copper bar heat dissipation surface 244. The three-phase copper bars 241 can be electrically connected to the IGBT module 22; the wound iron core 342 and the three-phase copper bars 241 are integrally injection-molded; the filtering magnetic ring 243 and the injection-molded housing of the three-phase copper bars 241 are sealed by dispensing; the three-phase copper bar heat dissipation surface 244 can be closely attached to the top of the integrated water channel thin film capacitor 21. The dispensing seal of the filtering magnetic ring 243 and the injection-molded housing of the three-phase copper bars 241 can prevent the risk of cracking of the plastic parts during power supply heating due to different thermal expansion coefficients between the two, and avoid the plastic slag falling inside the controller from affecting the electrical performance; the three-phase copper bar heat dissipation surface 244 being closely attached to the top of the integrated water channel thin film capacitor 21 greatly improves the heat dissipation efficiency.

[0067] In Figure 1 and Figure 2 In order to facilitate the subsequent sealing of the motor and the reducer inside the housing and ensure the integrity and reliability of the housing. In an embodiment of the present invention, the positions of the opening grooves on the housing can be various known to those skilled in the art. In order to facilitate the placement of machines such as motors in different opening grooves, the first opening groove 11 can be provided at the top of the housing; the second opening groove 13 can be provided on one side of the housing and cooperate with the rear cover outside the motor to seal the entire motor; the third opening groove 12 can be provided on the other side of the housing adjacent to the second opening groove 13 and cooperate with the rear cover outside the reducer to seal the entire reducer.

[0068] In Figure 1 In order to meet the heat dissipation effect of the housing 1. In an embodiment of the present invention, the housing 1 can include a second water channel (not marked in the figure), and the second water channel is provided inside the housing closely attached to the first opening groove 11 and the second opening groove 13; the controller and the motor share a heat dissipation water channel, reducing the water pipes and corresponding accessories and lowering the cost.

[0069] To meet the heat dissipation requirements within the water channel substrate and simplify the water channel distribution within the controller integration structure, in an embodiment of the present utility model, the water inlet and outlet of the first water channel are correspondingly connected to the second water channel, improving space utilization and heat dissipation performance.

[0070] In Figure 1 and Figure 2 Considering the sealing effect of the controller integration structure and improving the electromagnetic interference resistance performance. In an embodiment of the present utility model, the controller integration structure further includes a sealing cover plate 4, and the sealing cover plate 4 can be fixedly arranged on the first opening groove 11 to isolate the intrusion of external foreign objects and ensure the stable operation of the controller; a retaining wall 113 can be arranged between the first counterbore 111 and the second counterbore 112 to improve the electromagnetic interference resistance performance.

[0071] In Figure 1 To facilitate observing the internal situation of the controller integration structure without opening the sealing cover plate, in an embodiment of the present utility model, the sealing cover plate further includes an observation port 41 and a small cover plate 42. The observation port 41 is arranged at one end of the sealing cover plate 4 close to the second counterbore 112, and the small cover plate 42 is hermetically arranged on the observation port 41, meeting the requirement for observing the inside of the controller housing.

[0072] Through the above technical solutions, the controller integration structure realizes the integration of the motor housing, the reducer housing, and the controller housing by arranging a housing with three opening grooves for installing the motor, the reducer, and the controller, reducing the weight, reducing a large number of connecting parts, making the housing structure more compact, improving the housing strength, enhancing the NVH performance, and reducing the cost; and by arranging the inverter brick module to deeply integrate components such as the IGBT module, the PCB board, the water channel substrate, and the thin film capacitor, and arranging the filtering component to deeply integrate components such as the filter board and various capacitors, it further improves the heat dissipation efficiency and integration degree, reduces the material cost, greatly reduces the assembly complexity, improves the assembly fault tolerance rate and space utilization, and ensures the reliability of the product.

[0073] The preferred embodiments of the present utility model have been described in detail above in conjunction with the accompanying drawings. However, the present utility model is not limited to the specific details in the above embodiments. Within the scope of the technical concept of the present utility model, various simple modifications can be made to the technical solutions of the present utility model, and these simple modifications all fall within the protection scope of the present utility model. Additionally, it should be noted that in the above specific embodiments, the various specific technical features described can be combined in any suitable manner without conflict. To avoid unnecessary repetition, the present utility model will not separately describe various possible combination methods.

[0074] In addition, any combination can be made among various different embodiments of the present utility model, as long as it does not violate the idea of the present utility model, and it should equally be regarded as the content disclosed by the present utility model.

Claims

1. A controller integrated structure of a three-in-one integrated housing, characterized in that: The controller integrated structure comprises: A housing, the housing comprising: A first opening slot is used for installing a controller; The second opening slot is used for installing the motor; The third opening slot is used for installing the reducer; A first countersunk hole and a second countersunk hole are provided in the first opening groove, and the depth of the first countersunk hole is greater than the depth of the second countersunk hole; A filter assembly is disposed in the second countersunk hole; The inverter brick module is arranged in the first countersunk hole.

2. The controller integrated structure according to claim 1, characterized in that: The inverter brick module also includes: A film capacitor, the bottom of which is closely disposed on the bottom of the first countersunk hole; A water channel substrate, the bottom of which is arranged on the top of the film capacitor; An IGBT module, the IGBT module is fixedly arranged on the top of the waterway substrate; An IGBT sealing ring, sealingly arranged between the IGBT module arrangement and the water channel substrate; A three-phase current sensor is closely arranged on the top of the waterway substrate; A PCB board is arranged above the IGBT module and the three-phase current sensor; A chip protection clip is fixedly arranged on the PCB board.

3. The controller integrated structure according to claim 1, characterized in that: The filter assembly comprises: A positive copper busbar, arranged at one end of one side of the filter assembly; A negative copper busbar is arranged at one end of the other side of the filter assembly; A DC input terminal and a DC output terminal are electrically connected to the inverter brick module; A filter board, electrically connected to the DC input terminal and the DC output terminal, and arranged between the DC input terminal and the DC output terminal; The heat dissipation surface of the filter copper bar is closely attached to the bottom surface of the second countersunk hole.

4. The controller integrated structure according to claim 2, characterized in that: The water channel substrate and the film capacitor are designed as an integrated molding; The water channel substrate and the first countersunk hole are end-face sealed, and a bowl-shaped hole is provided on the side of the water channel substrate. The bowl-shaped hole cooperates with an external bowl-shaped hole plug to seal the first water channel in the water channel substrate.

5. The controller integrated structure according to claim 2, characterized in that: The three-phase current sensor comprises: Three-phase copper busbar; A wound iron core, wherein the wound iron core and the three-phase copper busbar are integrally injection molded; A filter magnetic ring, wherein the filter magnetic ring and the injection-molded housing of the three-phase copper busbar are sealed by a glue-dispensing cover; The heat dissipation surface of the three-phase copper bar is closely attached to the top of the water channel substrate.

6. The controller integrated structure according to claim 1, characterized in that: The first opening slot is arranged at the top of the shell; The second opening groove is arranged on one side of the housing and cooperates with the rear cover outside the motor to seal the entire motor; The third opening groove is disposed on the other side of the housing adjacent to the second opening groove, and cooperates with the rear cover outside the reducer to seal the entire reducer.

7. The controller integrated structure according to claim 4, characterized in that: The shell includes a second water channel, and the second water channel is arranged in the shell close to the first opening groove and the second opening groove.

8. The controller integrated structure according to claim 7, characterized in that: The water inlet and the water outlet of the first water channel are correspondingly connected to the second water channel.

9. The controller integrated structure according to claim 1, characterized in that: The controller integrated structure further comprises a sealing cover plate fixedly disposed on the first opening groove; A retaining wall is arranged between the first countersunk hole and the second countersunk hole.

10. The controller integrated structure according to claim 9, characterized in that: The sealing cover plate further comprises an observation port and a small cover plate. The observation port is arranged at one end of the sealing cover plate close to the second counterbore, and the small cover plate is sealingly arranged on the observation port.

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