Motor controller

Abstract

The utility model provides a motor controller. The motor controller comprises a shell, an electric connector, a power module and a direct current filter, the housing includes a port, a first chamber, and a second chamber separating the port and the first chamber. The electric connector is arranged at the port. The power module is arranged in the first cavity. The DC filter is arranged in the second chamber. The DC filter comprises a conductor and a magnetic ring. The conductor is electrically connected between the electric connector and the power module, and the magnetic ring is sleeved on the conductor. Therefore, the motor controller has good electromagnetic compatibility.

Description

Technical Field

[0001] The present disclosure relates to the field of motors, and more particularly to a motor controller. Background Art

[0002] Chinese Patent Application CN112994367A discloses an axially integrated electric vehicle motor control system. The power module is respectively connected to the output end of the thin-film capacitor and the input end of the three-phase output plate. The output end of the three-phase output plate is electrically connected to the three-phase input end of the drive motor. The input end of the thin-film capacitor passes through the center of the filter and is connected to the high-voltage bus plug-in.

[0003] However, the above motor control system may have electromagnetic compatibility (EMC) problems. For example, during the switching process, the voltage of the power module changes sharply, thus generating a large amount of electromagnetic radiation. These electromagnetic radiations may directly leave the motor control system via the high-voltage bus plug-in, resulting in poor electromagnetic compatibility of the motor control system. Summary of the Utility Model

[0004] In view of the state of the above prior art, the present disclosure is made. The purpose of the present disclosure is to provide a motor controller that can overcome at least one of the disadvantages described in the above background art.

[0005] To achieve the above purpose, the present disclosure adopts the following technical solutions.

[0006] The present disclosure provides a motor controller as follows, including: a housing, the housing includes a port, a first chamber, and a second chamber, the second chamber separates the port and the first chamber; an electrical connector, the electrical connector is disposed at the port; a power module, the power module is disposed in the first chamber; and a DC filter, the DC filter is disposed in the second chamber, the DC filter includes a conductor and a magnetic ring, the conductor is electrically connected between the electrical connector and the power module, and the magnetic ring is sleeved on the conductor.

[0007] In an alternative solution, the housing includes a partition wall and a shielding plate for shielding electromagnetic radiation, the partition wall separates a shielding groove inside the housing, the shielding plate covers the opening of the shielding groove, and the second chamber is disposed in the shielding groove.

[0008] In another alternative solution, the shielding plate is configured to fix the magnetic ring in the shielding groove.

[0009] In another alternative solution, the motor controller further includes an elastic element, the elastic element is disposed between the magnetic ring and the shielding plate, and is configured to press the magnetic ring and the shielding plate by elastic deformation.

[0010] In another alternative, the motor controller further includes a control board, which is electrically connected to the power module and fixedly covers the shielding board.

[0011] In another alternative, the power module includes a drive board, and the control board and the drive board include a shared circuit board.

[0012] In another alternative, the shielding board includes a first shielding portion and a second shielding portion. The first shielding portion covers the magnetic ring, the second shielding portion is covered by the control board, and a step is formed between the first shielding portion and the second shielding portion, such that at least a part of the control board is lower than the surface of the first shielding portion.

[0013] In another alternative, the power module includes an IGBT module, and the partition wall is disposed between the DC filter and the IGBT module.

[0014] In another alternative, the motor controller further includes an AC bus and an AC filter. The power module is electrically connected to the AC filter via the AC bus. The AC bus and the AC filter are disposed in the first chamber, and the partition wall is disposed between the DC filter and the AC bus.

[0015] In another alternative, the housing further includes a connection port. The first chamber communicates with the second chamber via the connection port. The port is disposed at one end of the second chamber, the connection port is disposed at the other end of the second chamber. The motor controller further includes a DC bus, and the DC filter is electrically connected to the power module via the DC bus, and the DC bus passes through the connection port.

[0016] By adopting the above technical solution, by separating the first port and the first chamber by the second chamber, the electromagnetic radiation generated by the power module is not easily bypassed by the first DC filter, but can be effectively dissipated by the magnetic ring, thereby reducing the electromagnetic radiation leaving the motor controller via the first electrical connector, so that the motor controller has good electromagnetic compatibility. Description of the Drawings

[0017] Figure 1 is a schematic diagram of a motor controller according to an embodiment of the present disclosure.

[0018] Figure 2 is Figure 1 a top view of the motor controller in

[0019] Figure 3 is Figure 1 an exploded view of the motor controller in

[0020] Figure 4 is Figure 1 a schematic diagram of the housing of the motor controller in

[0021] Description of the reference numerals in the drawings

[0022] 30 Motor controller

[0023] 32 Housing

[0024] 34 First electrical connector

[0025] 36 Power module

[0026] 38 First DC filter

[0027] 40 First port

[0028] 42 First chamber

[0029] 44 Second chamber

[0030] 45 X capacitor

[0031] 46 Ferrite core

[0032] 47 Y capacitor

[0033] 48 Partition wall

[0034] 50 Shielding plate

[0035] 52 Control board

[0036] 54 Driver board

[0037] 56 First shielding part

[0038] 58 Second shielding part

[0039] 60 Shielding groove

[0040] 62 IGBT module

[0041] 64 AC bus

[0042] 66 AC filter

[0043] 68 Connection port

[0044] 70 DC bus

[0045] 72 Support capacitor

[0046] 74 Second electrical connector

[0047] 76 Second port Detailed implementation manners

[0048] As shown Figure 1 In the embodiment of the present disclosure, a motor controller 30 is provided, especially a motor controller applicable to an electric vehicle motor.

[0049] As shown Figures 1 to 3 In the figure, the motor controller 30 includes a housing 32 (only partially shown in the figure), a first electrical connector 34 (an example of an electrical connector), a power module 36, and a first DC filter 38 (an example of a DC filter). The housing 32 includes a first port 40 (an example of a port), a first chamber 42, and a second chamber 44. The second chamber 44 separates the first port 40 from the first chamber 42. The first electrical connector 34 is disposed at the first port 40. The power module 36 is disposed in the first chamber 42. The first DC filter 38 is disposed in the second chamber 44. The first DC filter 38 includes a conductor and a magnetic ring 46. The conductor is electrically connected between the first electrical connector 34 and the power module 36, and the magnetic ring 46 is sleeved on the conductor.

[0050] In the technical solution provided by the embodiment of the present disclosure, by separating the first port 40 from the first chamber 42 by the second chamber 44, the electromagnetic radiation generated by the power module 36 is not easily bypassed by the first DC filter 38, but can be effectively dissipated by the magnetic ring 46, thereby reducing the electromagnetic radiation leaving the motor controller 30 via the first electrical connector 34, so that the motor controller 30 has better electromagnetic compatibility.

[0051] In some examples, the housing 32 can be integrated at the axial end of the motor.

[0052] In some examples, the first electrical connector 34 can be a commonly referred to high-voltage electrical connector, which is used to be electrically connected to an energy storage device such as a battery. For example, when the motor is a generator, the motor can supply electrical energy to the energy storage device via the first electrical connector 34; or when the motor is a motor, the energy storage device can supply electrical energy to the motor via the first electrical connector 34.

[0053] In some examples, the axial direction of the magnetic ring 46 can be orthogonal to the axial direction of the motor.

[0054] In some examples, as shown Figure 3 In the figure, the first DC filter 38 further includes an X capacitor 45 and a Y capacitor 47, and the X capacitor 45 and the Y capacitor 47 are electrically connected to the conductor passing through the magnetic ring 46.

[0055] In some examples, as shown Figure 3 and Figure 4 In the figure, the housing 32 includes a partition wall 48 and a shielding plate 50 for shielding electromagnetic radiation. The partition wall 48 separates a shielding groove 60 inside the housing 32, and the shielding plate 50 covers the opening of the shielding groove 60. The second chamber 44 is disposed in the shielding groove 60.

[0056] In some examples, such as Figure 3 shown, the partition wall 48 and the shielding plate 50 are formed as the wall portions of the second chamber 44.

[0057] In some examples, the partition wall 48 is provided with a plurality of mounting holes for receiving fasteners, such as threaded holes. The shielding plate 50 is fixedly mounted to the partition wall 48 by these fasteners.

[0058] In some examples, such as Figure 3 shown, the shielding plate 50 is configured to fix the magnetic ring 46 within the shielding groove 60. In this way, the magnetic ring 46 can be stably held within the shielding groove 60, thereby preventing the magnetic ring 46 from generating vibrations and noises. In addition, by fixing the magnetic ring 46 with the aid of the shielding plate 50, the motor controller 30 does not need to be provided with additional fixing measures, simplifying the structure of the motor controller 30.

[0059] In some examples, the motor controller 30 further includes an elastic element (not shown in the figure). The elastic element is disposed between the magnetic ring 46 and the shielding plate 50 and is configured to press against the magnetic ring 46 and the shielding plate 50 through elastic deformation. In this way, under the extrusion of the shielding plate 50, the elastically deformed elastic element can be in full contact with the magnetic ring 46 and press the magnetic ring 46 tightly, thereby better suppressing vibrations and noises. In addition, the elastic element can buffer the collision of the magnetic ring 46 against the shielding plate 50, playing a role in protecting the magnetic ring 46 and the shielding plate 50.

[0060] In some examples, the elastic element can be, for example, a foam.

[0061] In some examples, such as Figure 1 and Figure 2 shown, the motor controller 30 further includes a control board 52. The control board 52 is electrically connected to the power module 36 and fixedly covers the shielding plate 50. In this way, by arranging the shielding plate 50 and the control board 52 in a stacked manner, the motor controller 30 can have a compact structure.

[0062] In some examples, the thickness directions of the shielding plate 50 and the control board 52 can be parallel to the axial direction of the motor.

[0063] In some examples, such as Figures 1 to 3 shown, the power module 36 includes a drive board 54. The control board 52 and the drive board 54 include a common circuit board. In other words, at least part of the circuits of the control board 52 and at least part of the circuits of the drive board 54 are constructed on the same circuit board. In this way, the control board 52 and the drive board 54 can be arranged more compactly, and the assembly steps of the motor controller 30 can be simplified.

[0064] In some examples, such as Figure 2 andFigure 3 As shown, the shielding plate 50 includes a first shielding portion 56 and a second shielding portion 58. The first shielding portion 56 covers the magnetic ring 46, and the second shielding portion 58 is covered by the control board 52. A step is formed between the first shielding portion 56 and the second shielding portion 58, such that at least a part of the control board 52 is lower than the surface of the first shielding portion 56. Here, "lower" means closer to the shielding groove 60, and "surface" means the side facing away from the shielding groove 60. In this way, in the thickness direction of the shielding plate 50 and the control board 52, the first DC filter 38, the shielding plate 50, and the control board 52 can be arranged more compactly, so that the motor controller 30 can have a smaller size.

[0065] In some examples, the surface of the circuit board of the control board 52 can be lower than the surface of the first shielding portion 56.

[0066] In some examples, such as Figure 1 and Figure 3 As shown, the power module 36 further includes an IGBT module 62. A partition wall 48 is provided between the first DC filter 38 and the IGBT module 62. In this way, the partition wall 48 can block the electromagnetic radiation generated from the IGBT module 62 from propagating to the first electrical connector 34, thereby further improving the electromagnetic compatibility of the motor controller 30.

[0067] In some examples, such as Figures 1 to 3 As shown, the motor controller 30 further includes an AC bus 64 and an AC filter 66. The power module 36 is electrically connected to the AC filter 66 via the AC bus 64. The AC bus 64 and the AC filter 66 are arranged in the first chamber 42, and a partition wall 48 is provided between the first DC filter 38 and the AC bus 64. In this way, the partition wall 48 can block the electromagnetic radiation generated from the AC bus 64 from propagating to the first electrical connector 34, thereby further improving the electromagnetic compatibility of the motor controller 30.

[0068] In some examples, the AC filter 66 can be connected to the electrical connector of the motor for transmitting three-phase alternating current.

[0069] In some examples, such as Figure 3 and Figure 4As shown, the housing 32 further includes a connection port 68. The first chamber 42 communicates with the second chamber 44 via the connection port 68. The first port 40 is provided at one end of the second chamber 44, and the connection port 68 is provided at the other end of the second chamber 44 (the end opposite to the one end). The motor controller 30 further includes a DC bus 70. The first DC filter 38 is electrically connected to the power module 36 via the DC bus 70. The DC bus 70 passes through the connection port 68. In this way, by arranging the first port 40 and the connection port 68 at opposite ends of the second chamber 44, a relatively long distance can be achieved between the first port 40 and the connection port 68, so that the electromagnetic radiation entering the second chamber 44 via the connection port 68 is not likely to reach the first port 40, further improving the electromagnetic compatibility of the motor controller 30.

[0070] In some examples, as Figure 4 shown, the connection port 68 is formed by an intermittent portion between adjacent partition walls 48.

[0071] In some examples, as Figures 1 to 3 shown, the motor controller 30 further includes a support capacitor 72. The support capacitor 72 is electrically connected to the DC bus 70. Here, the support capacitor 72 is the so-called DC-Link.

[0072] In some examples, as Figures 1 to 3 shown, the motor controller 30 further includes a second electrical connector 74 and a second DC filter (not shown in the figure). The second electrical connector 74 is electrically connected to the control board 52 via the second DC filter.

[0073] In some examples, the second electrical connector 74 can be the so-called low-voltage electrical connector, which is used to supply power to the battery and electrical devices on the vehicle. Here, "low voltage" and "high voltage" are relative and not limited to specific numerical ranges. For example, "low voltage" can be 10V to 60V, and "high voltage" can be 400V to 800V.

[0074] In some examples, the second DC filter is disposed in the first chamber 42.

[0075] In some examples, the second DC filter includes a conductor electrically connected between the second electrical connector 74 and the control board 52 and a magnetic ring sleeved on the conductor.

[0076] In some examples, a partition wall 48 is provided between the first DC filter 38 and the second DC filter.

[0077] In some examples, as Figures 1 to 4 , the housing 32 further includes a second port 76. The second electrical connector 74 is disposed at the second port 76.

[0078] In some examples, asFigure 4 As shown, the first port 40 and the second port 76 are arranged opposite to each other.

[0079] The terms used in some embodiments of the present disclosure are only for explaining the embodiments of the present disclosure, rather than aiming to limit the present disclosure. Unless otherwise defined, the technical terms or scientific terms used in the embodiments of the present disclosure should have the ordinary meanings understood by those of ordinary skill in the field to which the present disclosure pertains. The "first", "second" and similar terms used in the specification and claims of the present disclosure do not indicate any order, quantity or importance, but are only used to distinguish different components. Similarly, the similar terms such as "a" or "an" do not indicate a quantity limitation, but indicate that there is at least one. The terms such as "comprising" or "including" mean that the elements or objects appearing before "comprising" or "including" cover the elements or objects listed after "comprising" or "including" and their equivalents, and do not exclude other elements or objects. The terms such as "upper", "lower", "left" and "right" are only used to indicate the relative position relationship. When the absolute position of the object being described changes, the relative position relationship may also change accordingly. "Plurality" means two or more, unless otherwise clearly defined.

[0080] The above are only optional embodiments of the present disclosure, and are not intended to limit the present disclosure. Any modifications, equivalent replacements, improvements, etc. made within the principles of the present disclosure shall be included within the protection scope of the present disclosure.

Claims

1. A motor controller, characterized in that, Comprising: A housing, the housing including a port, a first chamber, and a second chamber, the second chamber separating the port and the first chamber; An electrical connector disposed at the port; A power module disposed in the first chamber; And A DC filter disposed in the second chamber, the DC filter including a conductor and a magnetic ring, the conductor being electrically connected between the electrical connector and the power module, and the magnetic ring being sleeved on the conductor.

2. The motor controller according to claim 1, characterized in that The housing includes a partition wall and a shielding plate for shielding electromagnetic radiation, the partition wall partitioning a shielding groove inside the housing, the shielding plate covering an opening of the shielding groove, and the second chamber being disposed in the shielding groove.

3. The motor controller according to claim 2, wherein, The shielding plate is configured to fix the magnetic ring in the shielding groove.

4. The motor controller according to claim 3, wherein The motor controller further includes an elastic element disposed between the magnetic ring and the shielding plate and configured to press against the magnetic ring and the shielding plate through elastic deformation.

5. The motor controller according to claim 2, wherein, The motor controller further includes a control board electrically connected to the power module and fixedly covering the shielding plate.

6. The motor controller according to claim 5, characterized in that The power module includes a drive board, and the control board and the drive board include a common circuit board.

7. The motor controller according to claim 5, wherein The shielding plate includes a first shielding portion and a second shielding portion, the first shielding portion covering the magnetic ring, and the second shielding portion being covered by the control board, A step is formed between the first shielding portion and the second shielding portion such that at least a part of the control board is lower than a surface of the first shielding portion.

8. The motor controller according to claim 2, wherein, The power module includes an IGBT module, and the partition wall is disposed between the DC filter and the IGBT module.

9. The motor controller according to claim 2, wherein, The motor controller further includes an AC bus and an AC filter, the power module being electrically connected to the AC filter via the AC bus, the AC bus and the AC filter being disposed in the first chamber, and the partition wall being disposed between the DC filter and the AC bus.

10. The motor controller according to any one of claims 1 to 9, characterized in that, The housing further includes a connection port, the first chamber communicating with the second chamber via the connection port, the port being disposed at one end of the second chamber, and the connection port being disposed at the other end of the second chamber, The motor controller further includes a DC bus, the DC filter being electrically connected to the power module via the DC bus, and the DC bus passing through the connection port.

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