Integrated device and vehicle with same

Abstract

The utility model discloses an integrated device and a vehicle with the same, the integrated device is used for a motor controller, and the integrated device comprises a capacitor module, a power module and a housing; the shell is internally provided with a first accommodating cavity and a second accommodating cavity which are separated along a first direction, the power module is positioned in the first accommodating cavity, and the capacitor module is positioned in the second accommodating cavity; wherein one side, facing the shell, of the power module is provided with a liquid cooling flow channel, and the shell is provided with a liquid inlet and a liquid outlet which are communicated with the liquid cooling flow channel. According to the integrated device provided by the utility model, the capacitor module and the power module are integrated on one shell, so that the miniaturization of the integrated device is realized, the volume occupied by the integrated device in the shell of the motor controller is reduced, and the volume of the motor controller can be further reduced. The liquid cooling flow channel is defined between the shell and the power module, so that the arrangement mode of the liquid cooling flow channel is simple and compact, cooling liquid in the liquid cooling flow channel can perform heat dissipation on the power module and the capacitor module, and then the heat dissipation efficiency can be improved.

Description

Technical Field

[0001] The utility model relates to the technical field of motor controllers, and particularly relates to an integrated device and a vehicle having the same. Background Art

[0002] In the related art, currently, the power module and the capacitor module applied to the motor controller are separately installed and arranged inside the motor controller. In the housing of the motor controller, installation and fixing positions need to be designed separately for the capacitor module and the power module, which occupies a large amount of space and has complex internal connections, resulting in low overall space utilization rate. Summary of the Utility Model

[0003] The utility model aims to at least solve one of the technical problems existing in the prior art. For this purpose, an object of the utility model is to provide an integrated device, which integrates the capacitor module and the power module onto one housing to realize the miniaturization of the integrated device and reduce the volume of the motor controller.

[0004] The utility model also provides a vehicle having the above integrated device.

[0005] The integrated device according to the first aspect embodiment of the utility model is used for a motor controller, and includes: a capacitor module and a power module; a housing, wherein the housing has a first accommodation cavity and a second accommodation cavity separated along a first direction, the power module is located in the first accommodation cavity, and the capacitor module is located in the second accommodation cavity; wherein, there is a liquid cooling channel on a side of the power module facing the housing, and the housing has a liquid inlet and a liquid outlet communicated with the liquid cooling channel.

[0006] According to the integrated device of the utility model embodiment, the capacitor module and the power module are integrated onto one housing, so that the arrangement of the power module and the capacitor module is more compact, to realize the miniaturization of the capacitor module and the power module, reduce the volume occupied by the integrated device in the housing of the motor controller, and further reduce the volume of the motor controller. There is a liquid cooling channel on a side of the power module facing the housing, so that the setting mode of the liquid cooling channel is simple and compact. The cooling liquid in the liquid cooling channel can directly dissipate heat from the power module, and the cooling liquid can indirectly dissipate heat from the capacitor module through the housing, thereby improving the heat dissipation efficiency.

[0007] According to some embodiments of the utility model, the housing includes a partition board, the partition board is used for separating the first accommodation cavity and the second accommodation cavity, and a structure between the partition board and the power module forms the liquid cooling channel.

[0008] According to some embodiments of the present utility model, the housing further has an inlet flow channel and an outlet flow channel communicating with the liquid cooling flow channel. The inlet flow channel has the inlet, the outlet flow channel has the outlet, and both the inlet flow channel and the outlet flow channel extend along the first direction.

[0009] According to some embodiments of the present utility model, the inlet flow channel and the outlet flow channel are respectively located on two sides of the second accommodating cavity along the second direction, and the first direction is perpendicular to the second direction.

[0010] According to some embodiments of the present utility model, the power module includes a water-cooled substrate and a power component. The power component is connected to a side of the water-cooled substrate facing away from the housing. The first accommodating cavity has an opening on a side facing away from the second accommodating cavity, and the water-cooled substrate is used to close the opening.

[0011] According to some embodiments of the present utility model, the power component includes a power tube. A plurality of mounting seats are provided on a side of the water-cooled substrate facing away from the housing, and each mounting seat is adapted to mount the power tube.

[0012] According to some embodiments of the present utility model, the water-cooled substrate is provided with a plurality of heat dissipation columns. All the heat dissipation columns are located in the liquid cooling flow channel. The plurality of heat dissipation columns are arranged in multiple rows along the second direction, and adjacent rows of the heat dissipation columns are staggered along the third direction. Among them, the first direction, the second direction, and the third direction are perpendicular to each other in pairs.

[0013] According to some embodiments of the present utility model, the integrated device is located in a motor controller housing. The motor controller housing has an inlet communicating with the inlet and an outlet communicating with the outlet. A first sealing ring and a second sealing ring are provided between the housing and the motor controller housing. The first sealing ring seals between the inlet and the inlet, and the second sealing ring seals between the outlet and the outlet.

[0014] According to some embodiments of the present utility model, the integrated device is located in a motor controller housing. The housing has fixed feet, and the fixed feet are fixedly connected to the motor controller housing.

[0015] A vehicle according to an embodiment of the second aspect of the present utility model includes: a motor controller, the motor controller including a motor controller housing; and an integrated device according to the above embodiment of the first aspect of the present utility model, the integrated device being located in the motor controller housing.

[0016] According to the vehicle of the embodiment of the present utility model, by providing the above-mentioned integrated device, the volume occupied by the integrated device in the motor controller housing is reduced, the volume of the motor controller housing is reduced, and thus the volume of the motor controller can be reduced, and the power density of the motor controller can be increased.

[0017] Additional aspects and advantages of the present utility model will be given in part in the following description, become apparent in part from the following description, or be learned through the practice of the present utility model. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The above and / or additional aspects and advantages of the present utility model will become apparent and be readily understood from the description of the embodiments in conjunction with the following drawings, in which:

[0019] Figure 1 is an exploded view of an integrated device according to some embodiments of the present utility model;

[0020] Figure 2 is Figure 1 an exploded view of the integrated device in another direction in ;

[0021] Figure 3 is a cross-sectional view of an integrated device according to some embodiments of the present utility model;

[0022] Figure 4 is a schematic diagram of an integrated device separated from a motor controller housing according to some embodiments of the present utility model.

[0023] REFERENCE SIGNS:

[0024] 100, motor controller; 101, motor controller housing;

[0025] 10, integrated device;

[0026] 1, housing; 11, first accommodation cavity; 12, second accommodation cavity; 13, liquid cooling flow channel; 14, partition; 15, liquid inlet flow channel; 151, liquid inlet; 16, liquid outlet flow channel; 161, liquid outlet; 17, fixed support leg;

[0027] 2, capacitor module; 21, capacitor core; 22, positive copper busbar; 23, negative copper busbar;

[0028] 3, power module; 31, water-cooled substrate; 311, heat dissipation column; 32, power component; 321, power transistor;

[0029] 41, first sealing ring; 42, second sealing ring. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0030] Embodiments of the present utility model will be described in detail below. Examples of the embodiments are shown in the drawings, where the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the drawings are exemplary and are only used to explain the present utility model and should not be construed as a limitation of the present utility model.

[0031] In the description of the present utility model, it should be understood that the orientation or positional relationship indicated by the terms "upper", "lower", "front", "rear", "left", "right", etc. is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present utility model and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as a limitation of the present utility model. In addition, the terms "first" and "second" are only used for descriptive purposes and should not be construed as indicating or implying relative importance or implicitly indicating the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include one or more of such features. In the description of the present utility model, "a plurality" means two or more unless otherwise specifically defined.

[0032] In the description of the present utility model, it should be noted that unless otherwise clearly specified and limited, the terms "mounted", "connected", and "connected" should be understood in a broad sense. For example, it may be a fixed connection, a detachable connection, or an integral connection; it may be a mechanical connection or an electrical connection; it may be directly connected or indirectly connected through an intermediate medium, and it may be the internal communication of two elements or the interaction relationship between two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present utility model can be understood according to specific circumstances.

[0033] Next, reference is made to Figures 1-4 describe the integrated device 10 according to an embodiment of the present utility model.

[0034] The integrated device 10 according to an embodiment of the first aspect of the present utility model is for a motor controller 100, and the motor controller 100 is used to control the operation of a motor of a vehicle. By adjusting parameters such as current, voltage, and frequency, precise control of the start, stop, acceleration, deceleration, forward and reverse rotation, speed, and torque of the motor can be achieved.

[0035] The integrated device 10 includes a capacitor module 2, a power module 3, and a housing 1. The housing 1 has a first direction (for example, referring to the attached Figure 2The first accommodation cavity 11 and the second accommodation cavity 12 separated in the e1 direction in it. The power module 3 is located in the first accommodation cavity 11, and the capacitor module 2 is located in the second accommodation cavity 12. By arranging two non-connecting accommodation cavities in the housing 1 for placing the power module 3 and the capacitor module 2, the capacitor module 2 and the power module 3 can be integrated onto one housing 1, so as to realize the integrated setting of the power module 3 and the capacitor module 2, making the arrangement of the power module 3 and the capacitor module 2 more compact. After the integrated setting of the power module 3 and the capacitor module 2, it is also convenient for the assembly of the integrated device 10 on the production line.

[0036] Relative to the installation positions of separately arranging the capacitor module 2 and the power module 3 in the motor controller housing 101, placing the integrated device 10 after integrating the power module 3 and the capacitor module 2 in the motor controller housing 101 can reduce the volume occupied by the power module 3 and the capacitor module 2 in the motor controller housing 101, and thus can reduce the volume of the motor controller 100.

[0037] The capacitor module 2 and the power module 3 are separated and arranged, which can achieve the physical isolation of the capacitor module 2 and the power module 3, reduce the heat conduction between the capacitor module 2 and the power module 3, and reduce the thermal interference between the capacitor module 2 and the power module 3.

[0038] Among them, there is a liquid cooling flow path 13 on the side of the power module 3 facing the housing 1. The housing 1 has a liquid inlet 151 and a liquid outlet 161 communicating with the liquid cooling flow path 13, which can make the setting mode of the liquid cooling flow path 13 simple and compact. There is a coolant in the liquid cooling flow path 13. The coolant flows into the liquid cooling flow path 13 from the liquid inlet 151 and then flows out through the liquid outlet 161. When the coolant flows in the liquid cooling flow path 13, the coolant can directly contact the power module 3 and directly dissipate heat from the power module 3. When the coolant flows in the liquid cooling flow path 13, the heat of the coolant can be transferred to the capacitor module 2 through the housing 1 for dissipating heat from the capacitor module 2. For example, the housing 1 is integrally formed by die-casting process, which can increase the heat conduction efficiency of the housing 1, and thus can increase the heat exchange efficiency between the capacitor module 2 and the housing 1.

[0039] According to the integrated device 10 of the embodiment of the present invention, the capacitor module 2 and the power module 3 are integrated onto one housing 1, making the arrangement of the power module 3 and the capacitor module 2 more compact, so as to realize the miniaturization of the capacitor module 2 and the power module 3, reduce the volume occupied by the integrated device 10 in the motor controller housing 101, and thus can reduce the volume of the motor controller 100. There is a liquid cooling flow path 13 on the side of the power module 3 facing the housing 1, making the setting mode of the liquid cooling flow path 13 simple and compact. The coolant in the liquid cooling flow path 13 can directly dissipate heat from the power module 3, and the coolant can indirectly dissipate heat from the capacitor module 2 through the housing 1, thereby improving the heat dissipation efficiency.

[0040] According to some embodiments of the present invention, referring to Figures 1-3 , the housing 1 includes a partition 14 for separating the first accommodation cavity 11 and the second accommodation cavity 12. The power module 3 is located on one side of the partition 14 in the first direction, and the capacitor module 2 is located on the other side of the partition 14 in the first direction. A liquid cooling flow channel 13 is formed between the partition 14 and the power module 3. While cooling the power module 3, the coolant can also cool the capacitor module 2. By providing the liquid cooling flow channel 13 to cool the power module 3 and the capacitor module 2 simultaneously, the integration design of the liquid cooling flow channel 13 can be realized and the heat dissipation efficiency can be improved.

[0041] According to some embodiments of the present invention, referring to Figures 1-3 , the housing 1 further has an inlet flow channel 15 and an outlet flow channel 16. Both the inlet flow channel 15 and the outlet flow channel 16 are communicated with the liquid cooling flow channel 13. The inlet flow channel 15 has an inlet 151, and the outlet flow channel 16 has an outlet 161. Both the inlet flow channel 15 and the outlet flow channel 16 extend along the first direction, which can simplify the design of the inlet flow channel 15 and the outlet flow channel 16. For example, the inlet 151 and the outlet 161 can be arranged on the same side of the housing 1 in the first direction, which is convenient for external piping of the inlet 151 and the outlet 161.

[0042] According to some embodiments of the present invention, referring to Figures 1-3 , the inlet flow channel 15 and the outlet flow channel 16 are respectively located on both sides of the second accommodation cavity 12 along the second direction (for example, referring to the e2 direction in Figure 2 ), and the first direction is perpendicular to the second direction. The inlet flow channel 15 and the outlet flow channel 16 can simultaneously cool both sides of the capacitor module 2 along the second direction. When the coolant flows from the inlet 151 through the inlet flow channel 15, the liquid cooling flow channel 13, and the outlet flow channel 16, and then flows out through the outlet 161, three surfaces of the capacitor module 2 can be cooled, improving the heat dissipation efficiency of the capacitor module 2.

[0043] In a specific example, the capacitor module 2 includes a positive copper busbar 22, a capacitor core 21, and a negative copper busbar 23. The positive copper busbar 22 and the negative copper busbar 23 are respectively located on both sides of the capacitor core 21. The positive copper busbar 22, the negative copper busbar 23, and the capacitor core 21 are welded by resistance welding to form the capacitor module 2. The capacitor core 21 can be matched according to the different powers of the motor controller 100. After installing the capacitor module 2 into the second accommodation cavity 12, epoxy resin can be injected into the second accommodation cavity 12, and then high-temperature curing is carried out to fix the capacitor module 2.

[0044] According to some embodiments of the present invention, referring to Figures 1-3, the power module 3 includes a water-cooled substrate 31 and power components 32. The power components 32 are connected to the side of the water-cooled substrate 31 facing away from the housing 1. For example, the power components 32 are soldered to the water-cooled substrate 31 by vacuum reflow soldering or silver sintering soldering to form the power module 3. The first accommodation cavity 11 has an opening on the side facing away from the second accommodation cavity 12, and the water-cooled substrate 31 is used to close the opening. For example, the water-cooled substrate 31 can be welded to the housing 1 by friction welding. The power components 32 are located outside the first accommodation cavity 11, which can not only facilitate the heat dissipation of the power components 32, but also reduce the space of the housing 1 occupied by the power module 3, further realizing the miniaturization of the integrated device 10. For example, the power components 32 can be TPAK package devices.

[0045] In a specific example, a stepped surface is provided on the side wall of the first accommodation cavity 11, and the water-cooled substrate 31 is located on the stepped surface for defining the position of the water-cooled substrate 31 placed in the first accommodation cavity 11; when the water-cooled substrate 31 closes the opening of the first accommodation cavity 11, the outer surface of the water-cooled substrate 31 in the first direction is coplanar with the outer surface of the housing 1 in the first direction, which can improve the aesthetics after the assembly of the water-cooled substrate 31 and the housing 1, and also avoid the water-cooled substrate 31 protruding from the opening of the first accommodation cavity 11 and touching other parts.

[0046] According to some embodiments of the present invention, referring to Figures 1-3 , the power components 32 include power transistors 321. A plurality of mounting seats are provided on the side of the water-cooled substrate 31 facing away from the housing 1, and each mounting seat is suitable for mounting a power transistor 321. By providing a plurality of mounting seats on the water-cooled substrate 31, and each mounting seat can mount a power transistor 321, according to the power requirements of the motor controller 100, power transistors 321 can be mounted on all the mounting seats, or power transistors 321 can be mounted on some of the mounting seats. Different numbers of power transistors 321 can be arranged on the water-cooled substrate 31 to meet the power requirements of different power motor controllers 100, and the flexibility of use is strong.

[0047] For example, according to the different powers of the motor controller 100, power transistors 321 in parallel with 2 tubes, power transistors 321 in parallel with 3 tubes or power transistors 321 in parallel with 4 tubes can be mounted on the water-cooled substrate 31.

[0048] According to some embodiments of the present invention, referring to Figures 1-3, the water-cooled substrate 31 is provided with a plurality of heat dissipation columns 311, and the plurality of heat dissipation columns 311 are all located in the liquid cooling channel 13. Arranging the heat dissipation columns 311 in the liquid cooling channel 13 can increase the contact area between the coolant and the water-cooled substrate 31, so as to improve the heat exchange efficiency between the coolant and the water-cooled substrate 31. For example, the heat dissipation columns 311 can be in contact with the partition plate 14, and the cold quantity of the coolant can be transferred to the partition plate 14 through the plurality of heat dissipation columns 311. By exchanging heat between the partition plate 14 and the capacitor module 2, the heat dissipation efficiency of the capacitor module 2 can be improved.

[0049] The plurality of heat dissipation columns 311 are arranged in multiple rows along the second direction, and the heat dissipation columns 311 in adjacent rows are arranged in a staggered manner along the third direction (for example, referring to the Figure 2 e3 direction in the attached figure), where the first direction, the second direction, and the third direction are perpendicular to each other in pairs. The plurality of heat dissipation columns 311 are arranged irregularly, which can change the flow direction of the coolant in the liquid cooling channel 13 and can also control the flow rate of the coolant, so that the coolant can better dissipate heat from the power module 3 and the capacitor module 2.

[0050] According to some embodiments of the present invention, referring to Figures 1-4 , the integrated device 10 is located in the motor controller housing 101, and the motor controller housing 101 has an inlet communicating with the liquid inlet 151 and an outlet communicating with the liquid outlet 161. A first sealing ring 41 and a second sealing ring 42 are provided between the housing 1 and the motor controller housing 101. The first sealing ring 41 is sealed between the liquid inlet 151 and the inlet, preventing the coolant from leaking out from the connection between the liquid inlet 151 and the inlet; the second sealing ring 42 is sealed between the liquid outlet 161 and the outlet, preventing the coolant from leaking out from the connection between the liquid outlet 161 and the outlet, so as to meet the IP67 waterproof and dustproof rating requirements of the motor controller 100.

[0051] According to some embodiments of the present invention, referring to Figures 1-4 , the integrated device 10 is located in the motor controller housing 101, and the housing 1 has fixing feet 17, and the fixing feet 17 are fixedly connected to the motor controller housing 101. The fixing feet 17 can increase the stability of the integrated device 10 when installed in the motor controller housing 101. At the same time, by fixedly connecting the fixing feet 17 to the motor controller housing 101, the fixing method of the integrated device 10 can be made simple.

[0052] For example, the fixing feet 17 are provided with first connection holes, and the motor controller housing 101 is provided with second connection holes. The integrated device 10 can be detachably fixed in the motor controller housing 101 by passing fasteners through the first connection holes and the second connection holes in sequence.

[0053] A vehicle according to a second aspect embodiment of the present utility model includes: a motor controller 100, and the motor controller 100 includes a motor controller housing 101; an integration device 10 according to the above first aspect embodiment of the present utility model, and the integration device 10 is located inside the motor controller housing 101.

[0054] For the vehicle according to the embodiment of the present utility model, by providing the above integration device 10, the volume occupied by the integration device 10 inside the motor controller housing 101 is reduced, the volume of the motor controller housing 101 is reduced, and further the volume of the motor controller 100 can be reduced, and the power density of the motor controller 100 is increased.

[0055] In the description of this specification, the description with reference to terms such as "some embodiments", "optionally", "further", or "some examples", etc. means that the specific features, structures, materials, or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present utility model. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in a suitable manner in any one or more embodiments or examples.

[0056] Although the embodiments of the present utility model have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and purposes of the present utility model, and the scope of the present utility model is defined by the claims and their equivalents.

Claims

1. An integrated device for a motor controller, characterized in that, Comprising: A capacitor module and a power module; A housing having a first accommodation cavity and a second accommodation cavity separated along a first direction therein, the power module being located in the first accommodation cavity and the capacitor module being located in the second accommodation cavity; Wherein, one side of the power module facing the housing has a liquid cooling flow channel, and the housing has a liquid inlet and a liquid outlet communicating with the liquid cooling flow channel.

2. The integrated device according to claim 1, wherein The housing includes a partition for separating the first accommodation cavity and the second accommodation cavity, and a liquid cooling flow channel is formed between the partition and the power module.

3. The integrated device according to claim 2, wherein The housing further has a liquid inlet flow channel and a liquid outlet flow channel communicating with the liquid cooling flow channel, the liquid inlet flow channel has the liquid inlet, the liquid outlet flow channel has the liquid outlet, and both the liquid inlet flow channel and the liquid outlet flow channel extend along the first direction.

4. The integrated device according to claim 3, wherein The liquid inlet flow channel and the liquid outlet flow channel are respectively located on two sides of the second accommodation cavity along a second direction, and the first direction is perpendicular to the second direction.

5. The integrated device according to claim 1, characterized in that The power module includes a water-cooled substrate and power components, the power components being connected to a side of the water-cooled substrate facing away from the housing, and the first accommodation cavity has an opening on a side facing away from the second accommodation cavity, and the water-cooled substrate is used to close the opening.

6. The integrated device according to claim 5, wherein The power components include power tubes, and a plurality of mounting seats are provided on a side of the water-cooled substrate facing away from the housing, and each mounting seat is adapted to mount a power tube.

7. The integrated device according to claim 5, characterized in that, The water-cooled substrate is provided with a plurality of heat dissipation columns, all of the plurality of heat dissipation columns are located in the liquid cooling flow channel, the plurality of heat dissipation columns are arranged in multiple rows along the second direction, and adjacent rows of the heat dissipation columns are staggered along a third direction, wherein the first direction, the second direction and the third direction are perpendicular to each other in pairs.

8. The integrated device according to claim 1, wherein, The integrated device is located in a motor controller housing, and the motor controller housing has an inlet communicating with the liquid inlet and an outlet communicating with the liquid outlet. A first sealing ring and a second sealing ring are provided between the housing and the motor controller housing. The first sealing ring seals between the liquid inlet and the inlet, and the second sealing ring seals between the liquid outlet and the outlet.

9. The integrated device according to claim 1, wherein, The integrated device is located in a motor controller housing, and the housing has fixing feet fixedly connected to the motor controller housing.

10. A vehicle, characterized in that, Comprising: A motor controller, the motor controller including a motor controller housing; The integrated device according to any one of claims 1-9, the integrated device being located in the motor controller housing.

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