Motor controller

Abstract

The utility model belongs to the technical field of controllers, and provides a motor controller, which comprises a controller shell internally provided with a filter assembly, a thin-film capacitor and an IGBT (Insulated Gate Bipolar Translator) which are electrically connected in sequence; the driving control board covers the surfaces of the filter assembly, the thin-film capacitor and the IGBT, and the thin-film capacitor and the IGBT are electrically connected with the driving control board; and the water cooling unit is arranged at the bottom of the controller shell and is used for dissipating heat of the IGBT. According to the internal structure of the controller, the filter assembly, the thin-film capacitor, the IGBT, the water cooling unit and the like are designed in an integrated and compact manner, so that the installation space is effectively reduced; according to the utility model, the core component IGBT is arranged at the corresponding water cooling cavity, and the IGBT exchanges heat with the cooling water, so that the equipment reliability and the system stability can be effectively improved, a stable three-phase power supply which can be used by the motor is output, and the rotation of the motor is further realized.

Description

Technical Field

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

[0002] With the popularization of new energy vehicles, the electrification and intelligentization of transportation tools are gradually taking shape; among them, the electric drive design of passenger cars has become relatively mature; as one of the commonly used transportation tools, the controller of two-wheeled motorcycles needs to optimize the occupied space.

[0003] The main shortcoming of the two-wheeled motorcycle controller lies in its relatively large volume, and there is an urgent need for space optimization. The existing controllers are designed to be relatively large, which will have an adverse impact on the space layout and weight distribution of motorcycles. In addition, the double-layer board structure used in traditional controllers, including a metal shielding layer and a drive board, also causes waste of space. Although this structure helps to improve electromagnetic compatibility and heat dissipation effect, it also increases the design complexity and cost of the controller. Summary of the Utility Model

[0004] In view of the problems in the background art, the utility model proposes a motor controller.

[0005] In order to achieve the above purpose, the utility model adopts the following technical solutions:

[0006] A motor controller, comprising:

[0007] A controller housing, inside which a filter component, a thin film capacitor and an insulated gate bipolar transistor are sequentially electrically connected;

[0008] A drive control board, covering the surfaces of the filter component, the thin film capacitor and the insulated gate bipolar transistor, and both the thin film capacitor and the insulated gate bipolar transistor are electrically connected to the drive control board;

[0009] A water cooling unit, installed at the bottom of the controller housing, for dissipating heat from the insulated gate bipolar transistor.

[0010] Preferably, the filter component is connected to the inner bottom surface of the controller housing by bolts, and a negative copper bar and a positive copper bar are connected between the filter component and the thin film capacitor;

[0011] The thin film capacitor is connected to the inner bottom surface of the controller housing by screws, and is connected to the insulated gate bipolar transistor through a copper bar;

[0012] The insulated gate bipolar transistor is connected to the inner bottom surface of the controller housing by screws.

[0013] Preferably, a controller junction box is integrally connected to the bottom of the controller housing;

[0014] In the controller junction box, a DC high-voltage bus connected electrically to the filter assembly is installed.

[0015] The DC high-voltage bus extends outward through the controller junction box.

[0016] Preferably, the insulated gate bipolar transistor is also electrically connected to a three-phase copper busbar.

[0017] The connection terminals of the three-phase copper busbar extend to the outside of the controller housing.

[0018] Preferably, a transfer board is also electrically connected to the surface of the drive control board.

[0019] The transfer board is located inside the controller housing.

[0020] The transfer board is electrically connected to a wiring port, and the wiring port is located outside the controller housing and is installed at the bottom of the controller housing by screws.

[0021] Preferably, a pin header interface is provided on the surface of the drive control board, and the pin header interface is plugged into the transfer board and energized.

[0022] Preferably, the water cooling unit includes:

[0023] A water cooling cavity located at the position of the insulated gate bipolar transistor corresponding to the bottom of the controller housing.

[0024] A transition cavity communicating with the water cooling cavity and located below the water cooling cavity.

[0025] A water outlet opened at the bottom of the transition cavity.

[0026] Preferably, a water inlet flow channel is opened on the inner bottom surface of the water cooling cavity, and one end of the water inlet flow channel far from the water cooling cavity is connected to a water nozzle.

[0027] A communication port communicating with the transition cavity is also opened on the inner bottom surface of the water cooling cavity.

[0028] In the water cooling cavity, the water inlet flow channel is located at the starting end of the cooling water flow path, and the communication port is located at the ending end of the cooling water flow path.

[0029] Preferably, the controller housing is sealed and installed with a controller cover plate.

[0030] Preferably, a breather valve is installed on one side surface of the controller housing.

[0031] Advantages of the present utility model:

[0032] 1. In terms of the internal structure, the controller of the present utility model integrates and compactly designs components such as the filter assembly, thin film capacitor, insulated gate bipolar transistor, and water cooling unit, effectively reducing the installation space.

[0033] 2. The core component of the present utility model, the insulated gate bipolar transistor, is arranged at the corresponding water-cooling cavity. Through heat exchange with cooling water, water-cooled circulation heat dissipation is achieved, which can effectively improve the reliability of the equipment and the stability of the system, thereby outputting a stable three-phase power supply for the motor to use, and then realizing the rotation of the motor.

[0034] 3. The present utility model adopts an integrated design of the drive control board, reduces the use of low-voltage signal transfer wire harnesses and connectors, and replaces the traditional double-layer board structure (metal shielding board and drive board) with the drive control board, effectively reducing the height and volume of the controller.

[0035] Other features and advantages of the present utility model will be described in the following specification, and, in part, will become apparent from the specification or will be understood by implementing the present utility model. The objectives and other advantages of the present utility model can be achieved and obtained through the structures pointed out in the specification and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] In order to more clearly illustrate the technical solutions in the embodiments of the present utility model or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the following drawings are some embodiments of the present utility model. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0037] Figure 1 Shows a schematic top view of the motor controller of the present utility model;

[0038] Figure 2 Shows a schematic internal structure diagram of the motor controller of the present utility model;

[0039] Figure 3 Shows a schematic structural diagram of the drive control board of the present utility model;

[0040] Figure 4 Shows a schematic bottom view of the motor controller of the present utility model;

[0041] Figure 5 Shows a schematic structural diagram of the water-cooling cavity of the present utility model.

[0042] In the figure: 1. Controller cover plate; 2. Controller housing; 3. DC high-voltage bus; 4. Controller junction box; 5. Breather valve; 6. Three-phase fixed seat; 7. Filter component; 8. Negative copper busbar; 9. Positive copper busbar; 10. Thin-film capacitor; 11. Insulated gate bipolar transistor; 12. Three-phase copper busbar; 13. Adapter board; 14. Wiring port; 15. Water nozzle; 16. Transition cavity; 17. Water outlet; 18. Water-cooled cavity; 1801. Inlet water flow channel; 1802. Communication port; 19. Drive control board; 20. Pin header interface. Detailed implementation manners

[0043] To make the objectives, technical solutions and advantages of the embodiments of the present utility model clearer, the technical solutions in the embodiments of the present utility model will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present utility model. Apparently, the described embodiments are some but not all of the embodiments of the present utility model. 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.

[0044] A motor controller, as Figure 1 shown, includes a controller cover plate 1, a controller housing 2, a DC high-voltage bus 3, a controller junction box 4, a breather valve 5 and a three-phase fixed seat 6. The controller cover plate 1 and the controller housing 2 are connected by screws, and a sealing ring is also installed on the contact surface between the two. The DC high-voltage bus 3 enters the controller junction box 4 and is electrically connected to the devices inside the controller housing 2, and is fixed to the controller junction box 4 by bolts. The controller junction box 4 is located at the bottom of the controller housing 2 and is an integral structure with the controller housing 2; in addition, the controller junction box 4 is connected with a cover plate by screws, which is convenient for the staff to open for wiring operations. The breather valve 5 is of a snap-on type and is installed on one side of the controller housing 2, which can prevent water vapor and dust from entering the controller housing 2 while balancing the pressure difference inside and outside the controller.

[0045] In addition, a high-voltage warning label is also pasted on the controller housing 2 to warn of the high-voltage risk inside the product.

[0046] As Figure 2 shown, it is the internal structure diagram of the controller housing 2. Inside the housing, a filter component 7, a thin-film capacitor 10 and an IGBT (insulated gate bipolar transistor 11) are installed and electrically connected in sequence. The filter component 7 is close to the right inner wall of the controller housing 2; the thin-film capacitor 10 is located above the filter component 7 and close to the upper inner wall of the controller housing 2; the IGBT is located below the thin-film capacitor 10 and close to the left inner wall of the controller housing 2.

[0047] Furthermore, in Figure 2In it, the filter component 7 is connected to the inner bottom surface of the controller housing 2 by bolts, and the negative copper busbar 8 and the positive copper busbar 9 are bolted between the filter component 7 and the thin-film capacitor 10 to achieve current transfer between the filter component 7 and the thin-film capacitor 10. In addition, the thin-film capacitor 10 is screwed to the inner bottom surface of the controller housing 2 and is connected to the insulated gate bipolar transistor 11 through a copper busbar. It can transmit current to the insulated gate bipolar transistor 11 through its own copper busbar for the conversion of direct current and alternating current. The insulated gate bipolar transistor 11 is also screwed to the inner bottom surface of the controller housing 2. Moreover, a three-phase fixing seat 6 (screwed to the controller housing 2) is installed below the insulated gate bipolar transistor 11, and a three-phase copper busbar 12 electrically connected to the IBGT is installed on the three-phase fixing seat 6. The wiring ends of the three-phase copper busbar 12 extend to the outside of the controller housing 2 for connection to the motor.

[0048] It should be noted that in Figure 2 the three-phase copper busbar 12 includes a U-phase copper busbar ( Figure 2 the leftmost in Figure 2 ), a V-phase copper busbar, and a W-phase copper busbar (

[0049] the rightmost in Figure 3 ). The main function of the connection between the three-phase copper busbar 12 and the motor is to conduct current. As a connecting component, the copper busbar can efficiently transmit the three-phase alternating current output by the controller to the motor, ensuring that the motor can obtain sufficient electrical energy to drive the vehicle. In addition, the copper busbar also has good electrical conductivity and high-temperature resistance characteristics, and can withstand the large current and heat generated during the operation of the motor, ensuring the stability and safety of the system.

[0050] It should be noted that the drive control board 19 of the controller is connected to the thin-film capacitor 10 and the insulated gate bipolar transistor 11 through a specific circuit design. Generally, the thin-film capacitor 10 is connected to the power input terminal of the drive control board 19 and is used as a power filter to reduce power noise and stabilize the voltage. The insulated gate bipolar transistor 11, as a power switch element, its control terminal (gate) is controlled by the drive circuit on the drive control board 19. The drive control board 19 provides an appropriate gate voltage to turn on or off the insulated gate bipolar transistor 11, and at the same time ensures that the insulated gate bipolar transistor 11 operates within a safe operating area. The connection method usually includes electrical connection and physical installation to ensure the correct transmission of signals and power.

[0051] It should be further noted that the drive control board 19 replaces the traditional double-layer board structure (metal shielding board and drive board), effectively reducing the height and volume of the controller.

[0052] Combined Figure 2 、 Figure 3 and Figure 4 it can be known that the adapter board 13 is screw-connected inside the controller housing 2 ( Figure 2 in the lower right corner of ), which is electrically connected to the drive control board 19, and the adapter board 13 is also electrically connected to the wiring port 14. The wiring port 14 is located outside the controller housing 2 and is installed at the bottom of the controller housing 2 by screws.

[0053] It should be noted that pin headers 20 are reserved on the drive control board 19, and the drive control board 19 is plugged into and powered on the adapter board 13 through the pin headers 20. In the working state, external control signals can be transmitted to the adapter board 13 through the wiring port 14, and then to the drive control board 19. The drive control board 19 can adjust the thin-film capacitor 10 and the insulated gate bipolar transistor 11 according to the control signals.

[0054] It should be further noted that on the one hand, the wiring port 14 is fixed to the controller housing 2 by self-tapping bolts; on the other hand, it is fixed to the adapter board 13 by welding and the way of jointly fixing with self-tapping bolts.

[0055] In the controller, the working processes of the filter component 7, the thin-film capacitor 10, and the insulated gate bipolar transistor 11 are as follows:

[0056] The current of the power battery is transmitted to the filter component 7 through the DC high-voltage busbar 3, and filtering processing is carried out in the filter component 7. By filtering out the clutter and noise in the signal, the stability and reliability of the current are ensured; the filtered current is transmitted to the thin-film capacitor 10 through the positive copper row 9 and the negative copper row 8 for storage; on the other hand, after being stored by the thin-film capacitor 10, the current is relatively stable, preventing voltage overshoot and instantaneous voltage from affecting the insulated gate bipolar transistor 11. After passing through the insulated gate bipolar transistor 11, the direct current can be converted into three-phase alternating current used by the motor, and is transmitted to the motor through the U-phase copper row, V-phase copper row, and W-phase copper row on the three-phase fixing seat 6, realizing the conversion of electrical energy and mechanical energy.

[0057] Such as Figure 4As shown, a water cooling unit is also installed at the bottom of the controller housing 2, which is mainly used for dissipating heat from the insulated gate bipolar transistor 11. Specifically, the water cooling unit includes a water nozzle 15, a transition chamber 16, a water outlet 17, and a water cooling chamber 18. Among them, the water cooling chamber 18 is located at the bottom of the controller housing 2 corresponding to the insulated gate bipolar transistor 11; the transition chamber 16 is communicated with the water cooling chamber 18 and is located below the water cooling chamber 18; the water outlet 17 is opened at the bottom of the transition chamber 16.

[0058] Furthermore, in Figure 5 the inner bottom surface of the water cooling chamber 18 is provided with an inlet water flow channel 1801, and one end of the inlet water flow channel 1801 far away from the water cooling chamber 18 is connected with the water nozzle 15; the inner bottom surface of the water cooling chamber 18 is also provided with a communication port 1802 communicated with the transition chamber 16; in the water cooling chamber 18, the inlet water flow channel 1801 is located at the starting end of the cooling water flow path, and the communication port 1802 is located at the ending end of the cooling water flow path.

[0059] It should be noted that when the controller is working, the insulated gate bipolar transistor 11 will generate a large amount of heat. At this time, the cooling water enters the water cooling chamber 18 through the water nozzle 15, so as to exchange heat with the insulated gate bipolar transistor 11. Subsequently, the heated cooling water enters the transition chamber 16, and finally flows into the motor through the water outlet 17 to realize the circulation of the cooling water.

[0060] It should be further noted that through Figure 5 it can be known that the water cooling chamber 18 of the controller housing 2 is rectangular. Therefore, the inlet water flow channel 1801 can be arranged at the rightmost end, and the communication port 1802 can be arranged at the leftmost end (that is, the flow path of the cooling water is the longest when absorbing heat), so as to ensure that the cooling water can absorb the heat generated by the insulated gate bipolar transistor 11 to the greatest extent after entering the water cooling chamber 18.

[0061] Although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that: they can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements on some of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A motor controller, characterized in that, Comprising: A controller housing (2), inside which a filter component (7), a thin-film capacitor (10), and an insulated gate bipolar transistor (11) are sequentially installed and electrically connected; A drive control board (19), covering the surfaces of the filter component (7), the thin-film capacitor (10), and the insulated gate bipolar transistor (11), and both the thin-film capacitor (10) and the insulated gate bipolar transistor (11) are electrically connected to the drive control board (19); A water-cooling unit, installed at the bottom of the controller housing (2) for dissipating heat from the insulated gate bipolar transistor (11).

2. The motor controller according to claim 1, characterized in that, The filter component (7) is connected to the inner bottom surface of the controller housing (2) by bolts, and a negative copper busbar (8) and a positive copper busbar (9) are connected between the filter component (7) and the thin-film capacitor (10); The thin-film capacitor (10) is screwed to the inner bottom surface of the controller housing (2) and is connected to the insulated gate bipolar transistor (11) by a copper busbar; The insulated gate bipolar transistor (11) is screwed to the inner bottom surface of the controller housing (2).

3. The motor controller according to claim 2, wherein, A controller junction box (4) is integrally connected to the bottom of the controller housing (2); In the controller junction box (4), a DC high-voltage busbar (3) electrically connected to the filter component (7) is installed; The DC high-voltage busbar (3) extends outward through the controller junction box (4).

4. The motor controller according to claim 2, wherein The insulated gate bipolar transistor (11) is also electrically connected to a three-phase copper busbar (12); The connection terminals of the three-phase copper busbar (12) extend to the outside of the controller housing (2).

5. A motor controller according to claim 1, characterized in that A transfer board (13) is also electrically connected to the surface of the drive control board (19); The transfer board (13) is located inside the controller housing (2); The transfer board (13) is electrically connected to a wiring port (14), and the wiring port (14) is located outside the controller housing (2) and is installed at the bottom of the controller housing (2) by screws.

6. The motor controller according to claim 5, wherein, A pin header interface (20) is provided on the surface of the drive control board (19), and the pin header interface (20) is plugged into and energized with the transfer board (13).

7. A motor controller according to claim 1, wherein, The water-cooling unit includes: A water-cooling chamber (18), located at the bottom of the controller housing (2) corresponding to the position of the insulated gate bipolar transistor (11); A transition chamber (16), communicating with the water-cooling chamber (18) and located below the water-cooling chamber (18); An outlet (17), opened at the bottom of the transition chamber (16).

8. An electric machine controller according to claim 7, wherein, An inlet water flow channel (1801) is opened on the inner bottom surface of the water-cooling chamber (18), and one end of the inlet water flow channel (1801) far from the water-cooling chamber (18) is connected to a water nozzle (15); A communication port (1802) communicating with the transition chamber (16) is also opened on the inner bottom surface of the water-cooling chamber (18); Inside the water-cooling chamber (18), the inlet water flow channel (1801) is located at the starting end of the cooling water flow path, and the communication port (1802) is located at the ending end of the cooling water flow path.

9. A motor controller according to any one of claims 1-8, characterized in that, The controller housing (2) is sealed with a controller cover plate (1).

10. A motor controller according to any one of claims 1-8, characterized in that, A breather valve (5) is installed on one side of the controller housing (2).

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