Integrated motor controller

Abstract

The utility model discloses an integrated motor controller in the technical field of new energy automobiles, which comprises an electric drive axle assembly, the mounting end of the electric drive axle assembly is connected with an integrally formed controller casing, a mounting cavity with an opening on one side is arranged in the controller casing, and the opening side of the mounting cavity faces the electric drive axle assembly; a driving board, a thin-film capacitor, a three-phase output copper bar, a high-voltage filtering assembly, a low-voltage interface board and a main control board are arranged in the mounting cavity at intervals, and a heat dissipation assembly is further arranged in the mounting cavity; a traditional motor controller installation top cover is omitted, the traditional installation top cover is manufactured through the casting technology, the cost of the motor controller is reduced, the assembling steps are simplified, and the service life of components is prolonged.

Description

Technical Field

[0001] The utility model relates to the technical field of new energy vehicles, in particular to an integrated motor controller. Background Art

[0002] With the acceleration of the urbanization process, the demand for urban distribution and logistics transportation is increasing continuously, which promotes the growth of the demand in the new energy light truck market; especially with the rapid development of industries such as e-commerce and express delivery, the demand for light trucks in the urban distribution logistics market will continue to grow. However, such new energy light trucks have relatively strict requirements for the integration, lightweight and power density of the motor controller.

[0003] The traditional assembly sequence of the motor controller is that the motor controller control board is locked and welded with the motor controller control board, and then locked with the film capacitor after being attached to the heat dissipation water channel, and then installed in the motor controller housing. After that, the motor controller top cover is locked with the motor controller housing, and finally locked with the permanent magnet synchronous motor. Among them, both the motor controller housing and the top cover are casting parts, and the installation steps need to be further simplified and the cost is relatively high. Summary of the Utility Model

[0004] In order to overcome the deficiencies of the prior art, the technical problem to be solved by the utility model is: how to simplify the processing and installation steps of the motor controller and reduce the cost.

[0005] The technical solution adopted by the utility model to solve its technical problems is:

[0006] An integrated motor controller, including an electric drive axle assembly. An integrally formed controller housing is connected to the installation end of the electric drive axle assembly. An installation cavity with a single-side opening is arranged in the controller housing, and the opening side of the installation cavity faces the electric drive axle assembly; a drive board, a film capacitor, a three-phase output copper row, a high-voltage filtering component, a low-voltage interface board and a main control board are arranged at intervals in the installation cavity, and a heat dissipation component is also arranged in the installation cavity.

[0007] Further, the controller housing is a cast aluminum part.

[0008] Further, the installation cavity includes a first cavity and a second cavity respectively arranged on both sides of the controller housing. The drive board, the film capacitor, the three-phase output copper row, the high-voltage filtering component and the low-voltage interface board are respectively arranged at intervals in the first cavity, and the main control board is arranged in the second cavity. The first cavity is close to the electric drive axle assembly, and the second cavity is far from the electric drive axle assembly.

[0009] Further, the heat dissipation component includes a heat dissipation water channel opened on the controller housing, and the heat dissipation water channel is located between the first cavity and the second cavity.

[0010] Furthermore, a pressing cover is provided at the opening of the second cavity. The pressing cover is used to protect and press the main control board, and the pressing cover is a cast aluminum part.

[0011] Furthermore, the controller housing includes a first end and a second end. Inside the first cavity, a low-voltage interface board, the high-voltage filtering component, the thin-film capacitor, the drive board, and the three-phase output copper bar are sequentially arranged from the first end to the second end.

[0012] Furthermore, the shape and size of the second cavity are adapted to the shape and size of the main control board, and the position of the second cavity corresponds to the position of the drive board.

[0013] The beneficial effects of the present utility model are as follows:

[0014] Through the setting of the integrally formed controller housing, processing can be facilitated, and the design structure without a top cover can simplify the processing and installation processes, reduce costs and improve efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 is an exploded schematic view of the present utility model;

[0016] Figure 2 is a schematic view of the installation structure of the first cavity of the present utility model;

[0017] Figure 3 is a schematic view of the installation structure of the second cavity of the present utility model;

[0018] In the figure, the markings are as follows: 1 - electric drive bridge assembly, 2 - thin-film capacitor, 3 - low-voltage interface board, 4 - controller housing, 5 - high-voltage filtering component, 6 - pressing plate, 7 - locking device, 8 - main control board, 9 - three-phase output copper bar, 10 - drive board, 11 - first cavity, 12 - second cavity. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0019] The present utility model will be further described below with reference to the accompanying drawings.

[0020] According to Figures 1 - 3As shown in the figure, an embodiment of the present application proposes an integrated motor controller, which includes an electric drive bridge assembly 1. The installation end of the electric drive bridge assembly 1 is connected to an integrally formed controller housing 4. A one-sided open installation cavity is provided inside the controller housing 4, and the opening side of the installation cavity faces the electric drive bridge assembly 1. In the installation cavity, a drive board 10, a thin-film capacitor 2, a three-phase output copper busbar 9, a high-voltage filtering component 5, a low-voltage interface board 3, and a main control board 8 are arranged at intervals. A heat dissipation component is also provided in the installation cavity. Positioning columns, screw holes, and an insulating and sealing structure are provided in the installation cavity, which can ensure that each component can be stably installed in the installation cavity and the mutual influence and interference between components are small. During specific installation, the side of the controller housing 4 where the installation cavity is located is directly connected to the electric drive bridge assembly 1, without the need for subsequent connection of a top plate or cover plate. Through the integrally formed controller housing 4, processing is convenient, and the design structure without a top cover can simplify the processing and installation processes, reduce costs, and improve efficiency. Moreover, it can improve the problem of heat dissipation obstruction caused by the installation structure.

[0021] It should be noted that the above electric drive bridge assembly 1 is a body including a motor, a reducer, a differential, etc. that realizes a driving function, and the integrated motor controller proposed by the present invention is arranged on the wiring installation side of the electric drive bridge assembly 1 to provide an electric control function for the entire electric bridge driving process. Moreover, the controller housing 4 can be a casting. During the installation process of the entire structure, each component is directly installed in the installation cavity one by one, and then the controller housing 4 with the installed components is connected to the installation position of the electric drive bridge assembly 1 by means of bolt connection.

[0022] Specifically, the installation cavity includes a first cavity 11 and a second cavity 12 respectively arranged on both sides of the controller housing 4. The drive board 10, the thin-film capacitor 2, the three-phase output copper busbar 9, the high-voltage filtering component 5, and the low-voltage interface board 3 are respectively arranged at intervals in the first cavity 11, and the main control board 8 is arranged in the second cavity 12. The first cavity 11 is close to the electric drive bridge assembly 1, and the second cavity 12 is far from the electric drive bridge assembly 1. That is to say, the main control board 8 and other components are respectively arranged in two relatively independent cavities to achieve a relatively isolated effect and realize the influence of electromagnetic interference on each other.

[0023] Furthermore, the controller housing 4 includes a first end and a second end. In the first cavity 11, the low-voltage interface board 3, the high-voltage filtering component 5, the thin-film capacitor 2, the drive board 10, and the three-phase output copper busbar 9 are arranged in sequence from the first end to the second end. Such an arrangement and setting can facilitate the realization of an orderly installation process flow and improve the efficiency of the installation process.

[0024] The shape and size of the second cavity 12 are adapted to those of the main control board 8, and the position of the second cavity 12 corresponds to that of the drive board 10, ensuring the stability of the main control board 8 after installation and reducing jitter during operation.

[0025] Moreover, the heat dissipation component includes a heat dissipation water channel opened in the controller housing 4. The heat dissipation water channel is located between the first cavity 11 and the second cavity 12, and in the middle of the motor controller drive board 10 and the main control board 8. While dissipating heat from the power component IGBT of the drive board 10, it reduces the temperature of the cavity of the main control board 8, improving the service life of components. At the same time, when the heat dissipation water channel can play a role in shielding electromagnetic interference between the first cavity 11 and the second cavity 12, and the heat dissipation water channel can be multiple uniformly arranged ones or a completely open hollow cavity, which can further enhance the heat dissipation and cooling effect and the shielding and anti-interference effect.

[0026] In addition, a pressing cover is provided at the opening of the second cavity 12. The pressing cover is used to protect the main control board 8, and the pressing cover is a cast aluminum part. Through the setting of the pressing cover, the internal devices of the main control board 8 can be protected, further enhancing the anti-vibration performance of the PCB board of the main control board 8 inside the motor controller, reducing the failure rate, and having a good protection effect. The pressing plate 6 is provided with a locking device 7, which can specifically be a screw connection structure or a pin structure.

[0027] In summary, the present application proposes an integrated motor controller, including an electric drive bridge assembly 1. The installation end of the electric drive bridge assembly 1 is connected with an integrally formed controller housing 4. A single-sided open installation cavity is provided inside the controller housing 4, and the opening side of the installation cavity faces the electric drive bridge assembly 1; a drive board 10, a film capacitor 2, a three-phase output copper row 9, a high-voltage filtering component 5, a low-voltage interface board 3, and a main control board 8 are arranged at intervals inside the installation cavity. A heat dissipation component is also provided inside the installation cavity. The traditional installation top cover of the motor controller is cancelled. The installation top cover is made by casting process. Now, the integrated motor controller has a double-cavity structure. The top cover of the main control board 8 can be made by stamping process, reducing the cost of the motor controller and simplifying the assembly steps; the motor controller is designed with a double cavity, and the heat dissipation water channel is located between the drive board 10 and the main control board 8 of the motor controller. While dissipating heat from the power component IGBT of the drive board 10, it reduces the temperature of the cavity of the main control board 8, improving the service life of components; the motor controller is designed with a double cavity. The drive board 10 end of the motor controller will generate high electromagnetic interference during operation, and the heat dissipation water channel can play a role in shielding electromagnetic interference; the main control board 8 is locked in another cavity, which can enhance the anti-vibration performance of the PCB board inside the motor controller.

Claims

1. Integrated motor controller, characterized in that, It includes an electric drive axle assembly (1), and an integrally formed controller housing (4) is connected to the installation end of the electric drive axle assembly (1). A one-sided open installation cavity is provided in the controller housing (4), and the open side of the installation cavity faces the electric drive axle assembly (1); in the installation cavity, a drive board (10), a thin-film capacitor (2), a three-phase output copper busbar (9), a high-voltage filtering component (5), a low-voltage interface board (3), and a main control board (8) are arranged at intervals, and a heat dissipation component is also arranged in the installation cavity.

2. The integrated motor controller according to claim 1, wherein The controller housing (4) is a cast aluminum part.

3. The integrated motor controller according to claim 1, wherein The installation cavity includes a first cavity (11) and a second cavity (12) respectively arranged on both sides of the controller housing (4). The drive board (10), the thin-film capacitor (2), the three-phase output copper busbar (9), the high-voltage filtering component (5), and the low-voltage interface board (3) are respectively arranged at intervals in the first cavity (11), and the main control board (8) is arranged in the second cavity (12). The first cavity (11) is close to the electric drive axle assembly (1), and the second cavity (12) is far from the electric drive axle assembly (1).

4. The integrated motor controller according to claim 3, wherein The heat dissipation component includes a heat dissipation water channel opened in the controller housing (4), and the heat dissipation water channel is located between the first cavity (11) and the second cavity (12).

5. The integrated motor controller according to claim 4, wherein, A pressing cover is arranged at the opening of the second cavity (12), and the pressing cover is used to protect the main control board (8), and the pressing cover is a cast aluminum part.

6. The integrated motor controller according to claim 3, characterized in that, The controller housing (4) includes a first end and a second end. In the first cavity (11), a low-voltage interface board (3), the high-voltage filtering component (5), the thin-film capacitor (2), the drive board (10), and the three-phase output copper busbar (9) are arranged in sequence from the first end to the second end.

7. The integrated motor controller according to claim 6, wherein The shape and size of the second cavity (12) are adapted to the shape and size of the main control board (8), and the position of the second cavity (12) corresponds to the position of the drive board (10).

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