High-integration laminated motor controller

Abstract

The utility model relates to a high-integration laminated motor controller, which comprises a box cover, a box body, a control driving board, a filtering assembly, a two-phase assembly, a thin-film capacitor, a radiator, an IGBT (Insulated Gate Bipolar Translator) module, a steel vibration damping gasket and the like, a guide column is arranged in the box body; the two-phase support, the filtering support and the radiator are provided with two-phase support guide holes, filtering support guide holes and radiator installation guide holes respectively and are matched with the guide columns. And the thin-film capacitor, the radiator and the IGBT module are sequentially arranged in a laminated manner. Compared with the prior art, the guide columns and the guide holes are arranged, so that the whole assembly process is simplified, and the assembly rhythm of a production line is improved; the thin-film capacitor, the radiator and the IGBT module are sequentially arranged in a laminated mode, and the steel vibration buffering gasket is arranged between the capacitor and the box body and plays a role in vibration reduction and absorption of parts such as the capacitor, the module and the control drive board. And the annular reinforcing ribs are additionally arranged in the box cover, so that the modal inherent frequency of the box cover is improved, and the risk that the controller generates resonance is reduced.

Description

Technical Field

[0001] The utility model relates to a motor controller, in particular to a highly integrated laminated motor controller. Background Art

[0002] With the rapid development of new energy vehicles, the electric drive integrated system is more and more widely used, and people put forward higher requirements for the reliability and NVH of vehicle driving. During the driving process of the vehicle, the motor controller is not only affected by the vibration excitation from the road surface, but also affected by the vibration excitation of the motor and the reducer. The vibration excitation is amplified step by step along the propagation path of the assembly, threatening the service life of the components of the motor controller. In severe cases, the components will directly vibrate and fail, and the controller will stop running. Therefore, the design of the motor controller urgently needs to develop in the direction of vibration resistance. While meeting the vibration resistance performance, the internal layout of the motor controller is also more compact, which brings new problems. During the assembly process on the production line, there is less space for manual operation, making the assembly difficult, increasing the operation difficulty, and seriously affecting the production rhythm. Therefore, a method for facilitating production line assembly is needed to improve production efficiency.

[0003] The structure of the existing motor controller is as Figure 1 shown. The control board, drive board, film capacitor and module are placed inside the box body, and the module is closely attached to one side of the water-cooled plate for heat dissipation. The existing controller structure adopts the form of vertical split boards for the control board and the drive board. According to the vibration conduction path, the vibration excitation will be continuously amplified along the propagation path to the control board, affecting the service life of the components on the control board and the drive board. The whole controller housing is composed of too many components, which is not conducive to improving the overall mode of the controller and affects the NVH performance; and each component is relatively compact, and no reasonable guiding design is set. During the process of production line assembly, it will lead to an extended assembly time, affecting the production line capacity and increasing the labor cost.

[0004] After retrieval, the authorized announcement number CN216626344U discloses a motor controller, which specifically discloses: including an upper cover and a box body that enclose to form an accommodation cavity, and a filter module, a DC support capacitor, a cooling module, an IGBT module and a circuit board, an AC output module arranged in the accommodation cavity. Among them, the DC support capacitor is located in the first space of the accommodation cavity, the cooling module and the IGBT module are sequentially arranged above the DC support capacitor, the DC support capacitor is electrically connected to the IGBT module, the filter module is located in the second space of the accommodation cavity and is arranged at an interval from the DC support capacitor, the filter module is electrically connected to the DC support capacitor, the AC output module is located on the side of the DC support capacitor facing away from the filter module, and the AC output module is electrically connected to the IGBT module. The circuit board covers the filter module and the IGBT module, and the circuit board and the upper cover are connected via a conductive adhesive, and the circuit board is electrically connected to the IGBT module. However, the assembly process of this prior art is relatively cumbersome.

[0005] In summary, how to design a motor controller with a reasonable structure and a simplified assembly process is a technical problem to be solved. Utility Model Content

[0006] The purpose of the present utility model is to provide a highly integrated laminated motor controller to overcome the defect of the cumbersome assembly process in the above-mentioned prior art.

[0007] The purpose of the present utility model can be achieved through the following technical solutions:

[0008] According to one aspect of the present utility model, there is provided a highly integrated laminated motor controller, including a box cover, a box body, and a control and drive board, a filtering component, a two-phase component, a film capacitor, a radiator, an IGBT module, a current sensor, a three-phase component, and a low-voltage plug-in installed in the box body. The controller further includes a steel damping gasket located between the film capacitor and the box body; guiding columns are provided in the box body; the two-phase component includes a two-phase bracket, and guiding holes of the two-phase bracket are provided on the two-phase bracket; the filtering component includes a filtering bracket, and guiding holes of the filtering bracket are provided on the filtering bracket; guiding holes for radiator installation are provided on the radiator, and the guiding holes of the two-phase bracket, the guiding holes of the filtering bracket, and the guiding holes for radiator installation cooperate with the guiding columns; the film capacitor, the radiator, and the IGBT module are arranged in layers in sequence.

[0009] As a preferred technical solution, the box cover includes a large box cover and a small box cover. The small box cover is installed on the large box cover. Reinforcing ribs, a first guiding hole, and a second guiding hole are provided on the large box cover; the first guiding hole is opened on the reinforcing rib, and the second guiding hole is opened at two opposite corners of the large box cover.

[0010] As a preferred technical solution, the reinforcing ribs include annular reinforcing ribs and linear reinforcing ribs.

[0011] As a preferred technical solution, fixing holes for the bracket and fixing holes for the copper bar are further provided on the two-phase bracket. The two-phase bracket is installed on the box body through the fixing holes for the bracket; the two-phase component further includes a two-phase copper bar, and the two-phase copper bar is installed on the two-phase bracket through the fixing holes for the copper bar.

[0012] As a preferred technical solution, fixing holes for the capacitor copper bar and fixing holes for the filtering bracket are further provided on the filtering bracket; the filtering component is installed on the box body through the fixing holes for the filtering bracket; the filtering component further includes an adapter copper bar connected to the film capacitor through the fixing holes for the capacitor copper bar.

[0013] As a preferred technical solution, the radiator is further provided with a drive control board fixing hole, a water inlet, a module fixing hole, a capacitor fixing hole, a water outlet and a radiator fixing hole; the radiator is positioned through the radiator installation guiding hole and installed in the box body through the radiator fixing hole; the control drive board, the IGBT module and the thin film capacitor are respectively fixed on the radiator through the drive control board fixing hole, the module fixing hole and the capacitor fixing hole.

[0014] As a preferred technical solution, the steel damping gasket is installed on the bottom surface of the box body, and is provided with one or more elastic tongue structures which are in contact with one side of the capacitor.

[0015] As a preferred technical solution, the elastic tongue structure is rectangular, is provided with two creases, is connected with the steel damping gasket at one end, and is arc-shaped at the other end.

[0016] As a preferred technical solution, there are a plurality of the elastic tongue structures which are arranged in an array on the steel damping spring.

[0017] As a preferred technical solution, the guiding columns in the box body include a box cover guiding column, a two-phase bracket guiding column, a filter bracket guiding column and a radiator guiding column. The box cover guiding column is matched with the large box cover, the two-phase bracket guiding column is matched with the two-phase bracket guiding hole, the filter bracket guiding column is matched with the filter bracket guiding hole, and the radiator guiding column is matched with the radiator installation guiding hole.

[0018] Compared with the prior art, the utility model has the following beneficial effects:

[0019] 1) The utility model is provided with guiding columns or guiding holes on the box body, the two-phase bracket, the filter bracket and the radiator, which simplifies the whole assembly process, improves the assembly beat of the production line, enhances the working efficiency and greatly shortens the delivery cycle of the product; the thin film capacitor, the radiator and the IGBT module are arranged in a stacked manner in sequence, and a steel damping gasket is arranged between the capacitor and the box body, which plays a role in damping and vibration absorption for components such as the capacitor, the module and the control drive board;

[0020] 2) Based on the modal theory, the utility model additionally provides an annular reinforcing rib inside the box cover, which improves the modal natural frequency, enhances the overall controller mode, reduces the risk of resonance of the controller and ensures the service life of the internal components of the controller;

[0021] 3) The elastic tongue structure is arranged on the steel damping gasket of the utility model, which can achieve a better damping effect. Description of the Drawings

[0022] Figure 1 It is a schematic structural diagram of an existing motor controller;

[0023] Figure 2Schematic diagram of the overall structure of a highly integrated laminated motor controller according to the present utility model;

[0024] Figure 3 Schematic diagram of the large box cover structure according to the present utility model;

[0025] Figure 4 Schematic diagram of the two-phase bracket structure according to the present utility model;

[0026] Figure 5 Schematic diagram of the filter bracket structure according to the present utility model;

[0027] Figure 6 Schematic diagram of the radiator structure according to the present utility model;

[0028] Figure 7 Schematic diagram of the steel damping gasket spring piece structure according to the present utility model;

[0029] Figure 8 Schematic diagram of the box body structure according to the present utility model;

[0030] As indicated by the reference numerals in the figure:

[0031] 1. Large box cover, 2. Small box cover, 3. Copper column, 4. Control and drive board, 5. Filter component, 6. Two-phase component, 7. Box body, 8. Steel damping gasket, 9. Thin film capacitor, 10. Radiator, 11. IGBT module, 12. Current sensor, 13. Three-phase component, 14. Low-voltage plug-in, 1-1. Reinforcing rib, 1-2. First guiding hole, 1-3. Second guiding hole, 2-1. Two-phase bracket guiding hole, 2-2. Bracket fixing hole, 2-3. Copper bus fixing hole, 3-1. Filter bracket guiding hole, 3-2. Capacitor copper bus fixing hole, 3-3. Filter bracket fixing hole, 4-1. Control and drive board fixing hole, 4-2. Water inlet, 4-3. Module fixing hole, 4-4. Capacitor fixing hole, 4-5. Water outlet, 4-6. Radiator installation guiding hole, 4-7. Radiator fixing hole, 5-1. Tongue structure, 6-1. Box cover guiding column, 6-2. Two-phase bracket guiding column, 6-3. Filter bracket guiding column, 6-4. Radiator guiding column. Specific implementation manner

[0032] 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 a part of the embodiments of the present utility model, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present utility model without creative efforts shall fall within the protection scope of the present utility model.

[0033] As Figure 2As shown in the figure, the present utility model provides a highly integrated laminated motor controller, which adopts a laminated layout. Its main structure includes a box cover, copper columns 3, a control and drive board 4, a filtering component 5, a two-phase component 6, a box body 7, a steel damping pad 8, a thin-film capacitor 9, a radiator 10, an IGBT module 11, a current sensor 12, a three-phase component 13, and a low-voltage plug-in 14. The box cover includes a large box cover 1 and a small box cover 2, and the small box cover 2 is installed on the large box cover 1; the box cover is fixed on the box body, and the copper columns 3, the control and drive board 4, the filtering component 5, the two-phase component 6, the steel damping pad 8, the thin-film capacitor 9, the radiator 10, the IGBT module 11, the current sensor 12, the three-phase component 13, and the low-voltage plug-in 14 are installed inside the box body 7, and guide columns are provided inside the box body 7. The thin-film capacitor 9, the radiator 10, and the IGBT module 11 are arranged in a laminated manner in sequence, presenting a sandwich structure.

[0034] As Figure 3 shown, reinforcing ribs 1-11-1, a first guide hole 1-21-2, and a second guide hole 1-31-3 are provided on the back of the large box cover 11. The reinforcing ribs 1-11-1 include an annular reinforcing rib 1-1 and a linear reinforcing rib 1-1. The first guide hole 1-21-2 is opened on the reinforcing rib 1-11-1, and the second guide hole 1-31-3 is opened at two opposite corners of the large box cover 11. The first guide hole 1-21-2 and the second guide hole 1-31-3 are used for positioning during the assembly between the box cover and the box body 7. The annular reinforcing rib 1-11-1 effectively improves the modality of the box body 7.

[0035] By setting the reinforcing rib 1-1, the natural frequency of the large box cover 1 is increased to 1339 Hz. The natural frequency of an ordinary box cover is about 800 Hz. Therefore, the natural frequency of the large box cover 1 of the present utility model is increased by 67% compared with that of an ordinary box cover.

[0036] As Figure 4 shown, the two-phase component 6 includes a two-phase bracket and two-phase copper bars. Two-phase bracket guide holes 2-1, bracket fixing holes 2-2, and copper bar fixing holes 2-3 are provided on the two-phase bracket. The two-phase bracket guide holes 2-1 cooperate with the two-phase bracket guide columns 6-2 of the box body 7 for guiding the installation of the two-phase bracket and the box body 7; the bracket fixing holes 2-2 are used for locking the bracket and the box body 7, and the two-phase bracket is installed on the box body 7 through the bracket fixing holes 2-2; the copper bar fixing holes 2-3 are used for locking the two-phase copper bars, and the two-phase copper bars are installed on the two-phase bracket through the copper bar fixing holes 2-3.

[0037] As Figure 5As shown in the figure, the filtering component 5 includes a filtering support and a transition copper bar. The filtering support is provided with a filtering support guiding hole 3-1, a capacitor copper bar fixing hole 3-2, and a filtering support fixing hole 3-3. The filtering support guiding hole 3-1 is matched with the filtering support guiding column 6-3 of the box body 7 for guiding the installation of the filtering support and the box body 7; the capacitor copper bar fixing hole 3-2 is used for connecting the thin film capacitor 9 and the transition copper bar, and the transition copper bar is connected to the thin film capacitor 9 through the capacitor copper bar fixing hole 3-2; the filtering support fixing hole 3-3 is used for locking the filtering support and the box body 7, and the filtering component 5 is installed on the box body 7 through the filtering support fixing hole 3-3.

[0038] As Figure 6 shown in the figure, the radiator 10 is provided with a radiator installation guiding hole 4-6, a drive control board fixing hole, a water inlet 4-2, a module fixing hole 4-3, a capacitor fixing hole 4-4, a water outlet 4-5, and a radiator fixing hole 4-7. The radiator installation guiding hole 4-6 is matched with the radiator guiding column 6-4 of the box body 7 to safely and conveniently install the entire assembly formed by the radiator 10 and the IGBT module 11, the control drive board 4, and the thin film capacitor 9 assembled on the radiator 10 on the fixed surface of the box body 7, reducing the risk of component collision and failure caused by assembly errors and improving production efficiency; the drive control board fixing hole is used for partially fixing the drive control board; the water inlet 4-2 and the water outlet 4-5 are used for the inlet and outlet of cooling water and simultaneously dissipate heat for the IGBT module 11 and the thin film capacitor 9; the module fixing hole 4-3 is used for fixing the IGBT module 11 on the radiator 10; the capacitor fixing hole 4-4 is used for fixing the thin film capacitor 9 on the radiator 10; the radiator fixing hole 4-7 is used for locking and fixing the entire assembly formed by the radiator 10 and the IGBT module 11, the control drive board 4, and the thin film capacitor 9 assembled on the radiator 10. The radiator 10 is positioned through the radiator installation guiding hole 4-6 and installed in the box body 7 through the radiator fixing hole 4-7.

[0039] As Figure 7 shown in the figure, the steel damping gasket 8 is installed on the bottom surface of the box body 7, between the box body 7 and the thin film capacitor 9, and is provided with one or more elastic tongue structures 5-1. The elastic tongue structure 5-1 is in contact with one side of the capacitor; the elastic tongue structure 5-1 is rectangular, provided with two creases, connected to the steel damping gasket 8 at one end, and arc-shaped at the other end, for damping and buffering the assembly composed of the entire capacitor, IGBT module 11, and control drive board 4, and improving its vibration durability. 16 elastic tongue structures 5-1 are evenly distributed on the steel damping gasket 8 in the figure.

[0040] As Figure 8As shown, the guide posts on the box body 7 include the box cover guide post 6-1, the two-phase bracket guide post 6-2, the filter bracket guide post 6-3, and the radiator guide post 6-4. The box cover guide post 6-1 is used for the assembly guidance between the box cover and the box body 7, that is, the box cover guide post 6-1 cooperates with the large box cover 1; the two-phase bracket guide post 6-2 is used for the assembly guidance between the two-phase bracket and the box body 7, that is, the two-phase bracket guide post 6-2 cooperates with the two-phase bracket guide hole 2-1; the filter bracket guide post 6-3 is used for the assembly guidance between the filter bracket and the box body 7, that is, the filter bracket guide post 6-3 cooperates with the filter bracket guide hole 3-1; the radiator guide post 6-4 is used for the assembly guidance between the entire assembly formed by the IGBT module 11, the control drive board 4, and the thin film capacitor 9 assembled on the radiator 10 and the box body 7, that is, the radiator guide post 6-4 cooperates with the radiator installation guide hole 4-6. Even in a small operating space, it is convenient for production line operation, improves production efficiency, and reduces the risk of component collision failure caused by assembly errors.

[0041] The assembly steps of the present utility model are as follows:

[0042] 1) Assemble the two-phase component 6 in the controller box body 7;

[0043] 2) Lock the filter component 5 into the box body 7 and tighten and fix the copper busbar with bolts;

[0044] 3) Fix the thin film capacitor 9 on the back of the radiator 10 with bolts;

[0045] 4) Lock the IGBT module 11 onto the radiator 10;

[0046] 5) Lock and fix the control drive board 12 on the radiator 10 and the IGBT module 11, and solder the pins of the IGBT module 11;

[0047] 6) Install the steel damping gasket 8 in the box body 7 and lock the assembly of the capacitor 9, radiator 10, IGBT module 11, and control drive board 4 into the box body;

[0048] 7) Place the copper post 3 on the current sensor of the control drive board 4;

[0049] 8) Lock the three-phase component 13 into the box body 7 and fix it on the copper post with bolts;

[0050] 9) Lock the low-voltage plug-in 14 onto the large box cover 1;

[0051] 10) Lock the small box cover 2 onto the large box cover 1;

[0052] 11) Connect the low-voltage plug-in 14 to the control drive board 4 and fix the large box cover 1 on the box body 7 with bolts.

[0053] The utility model has the following advantages:

[0054] 1) It is easy to assemble on the production line. The utility model is designed with a compact structure, and at the same time, a guiding design is added to each component, which simplifies the entire assembly process, improves the assembly beat of the production line, enhances the work efficiency, and greatly shortens the product delivery cycle;

[0055] 2) It has a good anti-vibration effect. In the utility model, the thin-film capacitor 9, the radiator 10, and the IGBT module 11 are arranged in a laminated sandwich structure. By designing a steel damping gasket 8 under the thin-film capacitor 9, it plays a role in damping and absorbing vibration for components such as the thin-film capacitor 9, the IGBT module 11, and the control drive board 4;

[0056] 3) It has a relatively high mode. At the same time, based on the mode theory, a circular reinforcing rib 1-1 is added inside the box cover, so that its modal natural frequency reaches 1339 hz, and the natural frequency is increased by 67% compared with the general box cover, which improves the overall controller mode, reduces the risk of resonance of the controller, and ensures the service life of the internal components of the controller.

[0057] The above is only the specific implementation manner of the utility model, but the protection scope of the utility model is not limited thereto. Any person skilled in the art within the technical scope disclosed by the 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 utility model. Therefore, the protection scope of the utility model shall be subject to the protection scope of the claims.

Claims

1. A highly integrated stacked motor controller, comprising a box cover, a box body (7), and a control drive board (4), a filter component (5), a two-phase component (6), a thin-film capacitor (9), a radiator (10), an IGBT module (11), a current sensor (12), a three-phase component (13), and a low-voltage plug-in (14) installed in the box body (7), characterized in that, The controller further includes a steel damping gasket (8) located between the thin-film capacitor (9) and the box body (7); a guide post is provided inside the box body (7); the two-phase component (6) includes a two-phase bracket, and a two-phase bracket guide hole (2-1) is provided on the two-phase bracket; the filtering component (5) includes a filtering bracket, and a filtering bracket guide hole (3-1) is provided on the filtering bracket; a radiator mounting guide hole (4-6) is provided on the radiator (10), and the two-phase bracket guide hole (2-1), the filtering bracket guide hole (3-1) and the radiator mounting guide hole (4-6) are matched with the guide post; the thin-film capacitor (9), the radiator (10) and the IGBT module (11) are arranged in a stacked manner in sequence.

2. The high-integration laminated motor controller according to claim 1, wherein The box cover includes a large box cover (1) and a small box cover (2), the small box cover (2) is installed on the large box cover (1), and reinforcing ribs (1-1), a first guide hole (1-2) and a second guide hole (1-3) are provided on the large box cover (1); the first guide hole (1-2) is opened on the reinforcing rib (1-1), and the second guide hole (1-3) is opened at two opposite corners of the large box cover (1).

3. The high-integration laminated motor controller according to claim 2, wherein, The reinforcing rib (1-1) includes an annular reinforcing rib (1-1) and a linear reinforcing rib (1-1).

4. A highly integrated stacked motor controller according to claim 1, characterized in that, The two-phase bracket is further provided with a bracket fixing hole (2-2) and a copper bar fixing hole (2-3), and the two-phase bracket is installed on the box body (7) through the bracket fixing hole (2-2); the two-phase component (6) further includes a two-phase copper bar, and the two-phase copper bar is installed on the two-phase bracket through the copper bar fixing hole (2-3).

5. A highly integrated stacked motor controller according to claim 1, characterized in that, The filtering bracket is further provided with a capacitor copper bar fixing hole (3-2) and a filtering bracket fixing hole (3-3); the filtering component (5) is installed on the box body (7) through the filtering bracket fixing hole (3-3); the filtering component (5) further includes an adapter copper bar connected to the thin-film capacitor (9) through the capacitor copper bar fixing hole (3-2).

6. The high-integration laminated motor controller according to claim 1, wherein The radiator (10) is further provided with a drive control board fixing hole, a water inlet (4-2), a module fixing hole (4-3), a capacitor fixing hole (4-4), a water outlet (4-5) and a radiator fixing hole (4-7); the radiator (10) is positioned through the radiator mounting guide hole (4-6) and installed in the box body (7) through the radiator fixing hole (4-7); the control drive board (4), the IGBT module (11) and the thin-film capacitor (9) are respectively fixed on the radiator (10) through the drive control board fixing hole, the module fixing hole (4-3) and the capacitor fixing hole (4-4).

7. A highly integrated stacked motor controller according to claim 1, characterized in that The steel damping gasket (8) is installed on the bottom surface of the box body (7), and one or more elastic tongue structures (5-1) are provided thereon, and the elastic tongue structures (5-1) are in contact with one side of the capacitor.

8. A highly integrated stacked motor controller according to claim 7, characterized in that, The elastic tongue structure (5-1) is rectangular, with two creases provided thereon, one end is connected to the steel damping gasket (8), and the other end is arc-shaped.

9. A highly integrated stacked motor controller according to claim 7 or 8, characterized in that, There are multiple elastic tongue structures (5-1), which are arranged in an array on the steel damping gasket (8).

10. The high-integration laminated motor controller according to claim 1, characterized in that, The guide posts inside the box body (7) include a box cover guide post (6-1), two-phase support guide posts (6-2), a filter support guide post (6-3), and a radiator guide post (6-4). The box cover guide post (6-1) cooperates with the large box cover (1), the two-phase support guide posts (6-2) cooperate with the two-phase support guide holes (2-1), the filter support guide post (6-3) cooperates with the filter support guide holes (3-1), and the radiator guide post (6-4) cooperates with the radiator installation guide holes (4-6).

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