Motor controller and vehicle

Abstract

The utility model provides a motor controller and a vehicle. The motor controller comprises an end cover and a lower shell assembled below the end cover. The end cover comprises an inner layer, an outer layer and a mute layer located between the inner layer and the outer layer, and the mute layer is made of damping materials. The end cover is provided with a reinforcing part, and the reinforcing part comprises a first reinforcing part located in the middle of the end cover and second reinforcing parts arranged on the two sides of the first reinforcing part. And the first reinforcing part is arranged along the length direction of the end cover. According to the motor controller and the vehicle, the NVH performance can be improved.

Description

Technical Field

[0001] This application relates to the technical field of motors, and particularly to a motor controller and a vehicle. Background Art

[0002] The development of the electric drive system has brought about an improvement in efficiency, but at the same time, it has also brought new NVH performance problems. The driving motor replaces the traditional internal combustion engine, making the electromagnetic noise of the motor and the high-frequency whistling noise of the gear transmission system new problems that cannot be ignored in the drive system. This will make the driver feel irritable and uncomfortable, affecting the driver's driving behavior. At the same time, the integration of the electric drive motor causes a decrease in the overall stiffness of the system. Coupled with the high speed of the driving motor, which brings a wider system vibration frequency range, the electromagnetic excitation of the motor will cause a greater vibration response, increasing the possibility of system resonance.

[0003] Based on the requirement of lightweight, currently, the traditional motor body is mainly made of stamped aluminum alloy materials. It is difficult to increase the vibration frequency of the product from the body with thin-walled materials. Therefore, at present, only the auxiliary acoustic package scheme can be used to improve the NVH performance of the product, that is, to wrap the motor body to reduce the transmission of motor radiation noise. This traditional scheme has the following disadvantages: First, the cost is relatively high, and the selected acoustic package materials are all made of aluminum foil + non-woven fabric + PU leather materials; second, there are certain requirements for space layout, and sufficient installation space needs to be provided; third, the fixing method is particular, and fixing brackets need to be added around, which all pose higher requirements for the design of the motor.

[0004] Therefore, it is necessary to provide an improved motor controller and vehicle to solve the above problems. Utility Model Content

[0005] This application provides a motor controller and a vehicle for improving NVH performance.

[0006] This application discloses a motor controller, including an end cover and a lower case assembled under the end cover. The end cover includes an inner layer, an outer layer, and a sound insulation layer located between the inner layer and the outer layer. The sound insulation layer is a damping material; a strengthening portion is provided on the end cover. The strengthening portion includes a first strengthening portion located in the middle of the end cover and second strengthening portions provided on both sides of the first strengthening portion. The first strengthening portion is arranged along the length direction of the end cover.

[0007] Furthermore, the strengthening portions are symmetrically arranged; the second strengthening portions are arranged along the width direction of the end cover; the first strengthening portion and the second strengthening portions are connected by an arc transition.

[0008] Further, the length of the first reinforcing portion is 300 mm to 350 mm, and the width of the first reinforcing portion is 50 mm to 70 mm; the length of the second reinforcing portion is 150 mm to 200 mm, and the width of the second reinforcing portion is 80 mm to 100 mm.

[0009] Further, a plurality of mounting holes and positioning holes are provided on the end cover, and the diameter of the positioning hole is smaller than the diameter of the mounting hole.

[0010] Further, the end cover has a first side and a second side on both sides in the length direction and a third side and a fourth side on both sides in the width direction, and a plurality of mounting holes are provided at intervals on the first side, the second side, the third side and the fourth side.

[0011] Further, the positioning holes include a first positioning hole and a second positioning hole. The first positioning hole is provided between the two mounting holes on the first side, and the second positioning hole is provided at one end of the second side.

[0012] Further, the length of the end cover is 450 mm to 500 mm; the width of the end cover is 250 mm to 350 mm; the thickness of the end cover is 1.2 mm.

[0013] Further, both the inner layer and the outer layer are steel plates, and the sound insulation layer is bonded to the inner layer and the outer layer respectively; the tensile strength of the end cover is ≥290 MPa; the elongation rate of the end cover is ≥40%.

[0014] Further, the material of the sound insulation layer includes resin, rubber, antioxidant, lubricant and crosslinking agent.

[0015] The present application also discloses a vehicle, including the motor controller as described above.

[0016] By designing the end cover of the motor controller and vehicle of the present application as a three-layer composite structure and setting the sound insulation layer in the middle as a damping material with strong sound insulation effect, the resonance of the end cover is effectively suppressed, and the NVH performance of the motor controller is improved. By providing a reinforcing portion on the end cover, the structural strength and stiffness of the motor controller are improved, so that the motor controller can meet the performance requirements such as mode and strength. At the same time, the first reinforcing portion is arranged along the length direction of the end cover, so that the force on the end cover is more uniform and it is convenient for production and manufacturing.

[0017] It should be understood that the above general description and the following detailed description are only exemplary and explanatory, and cannot limit this specification. Description of the Drawings

[0018] The accompanying drawings here are incorporated into the specification and form a part of this specification, showing embodiments consistent with this specification, and are used together with the specification to explain the principles of this specification.

[0019] Figure 1 It is a schematic structural diagram of the motor controller of this application.

[0020] Figure 2 It is a schematic structural diagram of the end cover of the motor controller of this application.

[0021] Figure 3 is Figure 1 A partial sectional view of the end cover of the motor controller in

[0022] Figure 4 is Figure 1 The front view of the end cover of the motor controller in

[0023] Figure 5 It is the in-vehicle noise spectrum diagram of the motor controller of this application during CAE simulation analysis.

[0024] Figure 6 It is the noise curve diagram of the motor controller of this application during CAE simulation analysis.

[0025] Explanation of the reference numerals in the drawings:

[0026] 10. End cover; 101. Inner layer; 102. Outer layer; 103. Sound insulation layer; 104. First side; 105. Second side; 106. Third side; 107. Fourth side; 11. Reinforcing part; 111. First reinforcing part; 112. Second reinforcing part; 12. Mounting hole; 13. Positioning hole; 131. First positioning hole; 132. Second positioning hole; 20. Lower shell; 30. Fastener. Detailed implementation manners

[0027] Here, the technical solutions in the embodiments (or "implementation manners") of this application will be clearly and completely described in conjunction with the accompanying drawings. When the following description involves the accompanying drawings, unless otherwise indicated, the same numerals in different drawings represent the same or similar elements.

[0028] If there are terms related to directional indication or positional relationship in the embodiments of the present application (such as up, down, left, right, front, back, inside, outside, top, bottom, center, vertical, horizontal, longitudinal, transverse, length, width, counterclockwise, clockwise, axial, radial, circumferential, etc.), such terms are only used to explain the relative positional relationship and movement conditions between components in a specific posture (as shown in the drawings); if the specific posture changes, the directional indication or positional relationship will also change accordingly. In addition, the terms "first", "second", etc. involved in the embodiments of the present application are only for the purpose of convenient description and cannot be understood as indicating or implying relative importance.

[0029] Next, the embodiments of the present application will be described in detail. In the present application, the inner side refers to the side of the motor controller end cover 10 close to the motor controller lower housing 20, and the outer side refers to the side of the motor controller end cover 10 far from the motor controller lower housing 20.

[0030] As Figures 1 to 3 shown, the present application provides a motor controller, including an end cover 10 and a lower housing 20, and the lower housing 20 is assembled below the end cover 10.

[0031] The end cover 10 includes an inner layer 101, an outer layer 102, and a sound insulation layer 103 located between the inner layer 101 and the outer layer 102. Both the inner layer 101 and the outer layer 102 are steel plates, and the sound insulation layer 103 is a damping material, and the sound insulation layer 103 is adhesively bonded to the inner layer 101 and the outer layer 102 respectively. Specifically, both the inner layer 101 and the outer layer 102 of the present application adopt steel plate materials of the deep drawing type DC series. The sound insulation layer 103 adopts a polymer sound insulation damping material, and its composition includes resin, rubber, antioxidant, lubricant, crosslinking agent, and other additives, etc.

[0032] By designing the end cover 10 as a composite structure of metal-damping material-metal, the characteristics of metal materials and polymer materials are effectively combined and used together, so that the end cover 10 not only has the original mechanical properties and processing and forming characteristics of metal materials, but also has damping characteristics. It can suppress the resonance generated when the driving motor order noise and the inverter switching frequency noise are conducted to the end cover 10, effectively reduce the system noise of the motor controller, and improve the NVH performance of the motor controller.

[0033] In the sound insulation layer 103 of this embodiment, the weight percentage of the butadiene-acrylonitrile mixture is 35% - 40%; the weight percentage of bisphenol A epoxy resin is 35% - 40%; the weight percentage of phenolic resin is 15% - 20%; the weight percentage of antioxidant 1010 is 0.5% - 1.5%; the lubricant is zinc stearate, and the weight percentage is 0.5% - 1.5%; the crosslinking agent is maleic anhydride, and the weight percentage is 0.5% - 1.5%; the weight percentage of other additives is 3% - 5%.

[0034] End cap 10 utilizes a composite structure with a tensile strength of ≥290 MPa, a yield strength of ≥190 MPa, and an elongation of ≥40%. Compared to traditional materials, the material used in end cap 10 reduces sound insulation by over 10 dB. By adjusting the material formulation, the overall vehicle NVH performance can be reduced by over 1 dB.

[0035] The end cap 10 is approximately rectangular in shape, with an overall length of 450 mm to 500 mm and an overall width of 250 mm to 350 mm. The overall thickness of the inner layer 101, outer layer 102, and silent layer 103 is 1.2 mm. It is understood that the shape and size of the end cap 10, as well as the specific material composition of the inner layer 101, outer layer 102, and silent layer 103, can be designed differently based on actual needs.

[0036] Please also refer to Figure 4 The end cap 10 is provided with a reinforcement portion 11, which protrudes outward as a whole and is symmetrically arranged. The reinforcement portion 11 includes a first reinforcement portion 111 and a second reinforcement portion 112. The first reinforcement portion 111 is provided along the length direction of the end cap 10 and is located in the middle of the end cap 10. The second reinforcement portion 112 is provided along the width direction of the end cap 10 and is located on both sides of the first reinforcement portion 111.

[0037] Furthermore, the reinforcement portion 11 is shaped like a "卄". There is one first reinforcement portion 111 and two second reinforcement portions 112. The first reinforcement portion 111 passes through the two second reinforcement portions 112 in the length direction of the end cover 10.

[0038] Providing reinforcement 11 on end cap 10 effectively improves its rigidity and structural strength, making it more resistant to deformation when subjected to external forces, thereby enhancing its reliability and stability. Furthermore, the design of reinforcement 11 effectively disperses and absorbs vibration generated by the motor, thereby reducing vibration and noise levels within the motor controller and improving overall NVH performance.

[0039] By symmetrically arranging the reinforcements 11, the stress distribution across the end cap 10 is further uniform, helping to reduce structural deformation and enhance the overall stability of the motor controller. The reinforcements 11 are simple in structure, making them easy to manufacture and also helping to optimize the overall structural layout of the motor controller, improving space utilization.

[0040] Specifically, the protruding height of the reinforcing part 11 is 4 mm to 6 mm. The length of the first reinforcing part 111 is 300 mm to 350 mm, and the width of the first reinforcing part 111 is 50 mm to 70 mm. The length of the second reinforcing part 112 is 150 mm to 200 mm, and the width of the second reinforcing part 112 is 80 mm to 100 mm. The corners of each end of the reinforcing part 11 are transitioned with arcs, and the first reinforcing part 111 and the second reinforcing part 112 are transitioned and connected with arcs, making the stress distribution of the reinforcing part 11 more uniform. The transition radian is 3°.

[0041] The end cover 10 is provided with mounting holes 12 and positioning holes 13. Both the mounting holes 12 and the positioning holes 13 fix the end cover 10 on the lower housing 20 by cooperating with the fasteners 30. The number of the mounting holes 12 is several, and they are all distributed at the edge of the end cover 10.

[0042] Specifically, as Figure 4 shown, the end cover 10 has a first side 104, a second side 105, a third side 106 and a fourth side 107. The first side 104 and the second side 105 are respectively located on both sides of the length direction of the end cover 10, and the third side 106 and the fourth side 107 are respectively located on both sides of the width direction of the end cover 10. A number of mounting holes 12 are evenly arranged on the first side 104, the second side 105, the third side 106 and the fourth side 107, providing more docking points for the connection between the end cover 10 and the lower housing 20, making the connection between the end cover 10 and the lower housing 20 more stable and reliable, and improving the stability and docking accuracy of the motor controller.

[0043] In this embodiment, four mounting holes 12 are provided on both the first side 104 and the second side 105. The four mounting holes 12 are evenly distributed, and the distance between adjacent two mounting holes 12 is 40 mm. Six evenly distributed mounting holes 12 are provided on the fourth side 107, and the distance between adjacent two mounting holes 12 is 40 mm. Seven mounting holes 12 are provided on the third side 106. The distance between one mounting hole 12 at the end of the third side 106 and its nearest mounting hole 12 is 25 mm, and the remaining six mounting holes 12 are evenly distributed, and the distance between adjacent two mounting holes 12 is 35 mm.

[0044] As described above, a total of 21 mounting holes 12 are provided on the end cover 10 of this embodiment. The aperture of the 21 mounting holes 12 is 14 mm, and the pitch is 1.5 mm.

[0045] The positioning holes 13 include a first positioning hole 131 and a second positioning hole 132. The number of the first positioning holes 131 is one, which is provided on the first side 104 and is located between two mounting holes 12 on the first side 104. The number of the second positioning holes 132 is one, which is provided on the second side 105 and is located at one end of the second side 105.

[0046] The aperture of the positioning hole 13 is smaller than that of the mounting hole 12. Specifically, the aperture of the first positioning hole 131 is 8 mm, and the pitch is 0.75 mm. The aperture of the second positioning hole 132 is 10 mm, and the pitch is 1 mm. The fasteners 30 are all M14 bolts.

[0047] By setting the mounting hole 12 to cooperate with the fastener 30, the connection between the end cover 10 and the lower shell 20 is made more firm, effectively improving the structural stability of the motor controller. Setting the position and aperture size of the mounting hole 12 in advance at the edge of the end cover 10 enables quick and accurate fixation during the assembly process of the motor controller. In addition, when maintenance or component replacement is required, it is also convenient for quick disassembly, improving the convenience of maintenance.

[0048] On the one hand, the positioning hole 13 can provide accurate positioning during the assembly of the end cover 10 and the lower shell 20, facilitating the assembly of the motor controller. On the other hand, it strengthens the connection stability between the end cover 10 and the lower shell 20. It can be understood that the number, position distribution, and size of the mounting hole 12 and the positioning hole 13 can be flexibly set according to actual needs, and this application does not limit this.

[0049] The following explains the structural design process of the end cover 10 of the motor controller of this application:

[0050] Step 1: Based on the stamping requirements and NVH performance requirements, confirm the structural cross-section form and parameters of the composite soundproof material. The structure of the designed motor controller is as described above.

[0051] Step 2: Conduct a CAE simulation performance analysis on the designed motor controller housing. By evaluating the modal performance, static strength, and NVH performance conditions of the structure, determine whether it meets the design requirements of the target motor controller.

[0052] To better reflect the rationality of the structural design, the end cover 10 of the motor controller is installed and fixed to the lower shell 20 with M14 bolts to form the product assembly of the motor controller, and then a performance CAE analysis test is further carried out on the product assembly.

[0053] Considering the vehicle resonance problem, first evaluate the modal performance of the motor controller. The analysis results are shown in Table 1: The first-order mode of the motor controller assembly is 366.77 Hz, and the second-order mode is 392.37 Hz, both higher than the design requirements of the vehicle product.

[0054]

[0055] Table 1

[0056] Secondly, for the analysis requirements of the bolt strength of the motor controller, it is necessary to analyze and verify according to the M14 bolt loaded with a torque of 130 N·m, and it is required that the maximum stress borne by the motor controller be less than the yield strength of the material.

[0057] The analysis results are shown in Table 2: From the X-direction strength analysis, the maximum stress intensity of the end cover 10 is 20.44 MPa, which is much less than the yield strength of 190 MPa of the DC01 steel plate. From the Y-direction strength analysis, the maximum stress intensity of the end cover 10 is 10.274 MPa, which is also much less than the yield strength of 190 MPa of the DC01 steel plate. From the Z-direction strength analysis, the maximum stress intensity of the end cover 10 is 19.246 MPa, which is much less than the yield strength of 190 MPa of the DC01 steel plate.

[0058]

[0059] Table 2

[0060] Finally, the NVH performance is evaluated, and the analysis results of the motor controller adopting the present application and the motor controller with traditional steel plate materials are compared and analyzed. As Figure 5 and Figure 6 shown, the results show that: when accelerating at 78 km / h, the noise of the electric drive axle mainly comes from the motor shaft gear, but the evaluation of the in-vehicle noise effect is reduced by more than 2 dB compared with the traditional steel plate noise evaluation.

[0061] Through the above performance analysis, the structural design of the motor controller of the present application can meet the design requirements of the motor controller assembly of the heavy truck model, achieve the NVH and strength performance goals, and can be widely applied to the heavy truck model.

[0062] Step 3: According to the structural design and analysis results of the product, determine the material formula and processing technology of the motor controller end cover, and carry out the preparation.

[0063] Mix the raw materials of each formula of the sound insulation layer 103 evenly in the reactor according to the weight ratio. Treat the DC01 steel plates of the inner layer 101 and the outer layer 102 with reagents such as acetone and methyl ethyl ketone on the surface respectively. Then evenly coat the mixed sound insulation layer 103 material on the outer side of the inner layer 101 and the inner side of the outer layer 102 through a coater, and the coating thickness is 0.03 - 0.8 mm. The coated inner layer 101 and outer layer 102 respectively enter a preheating machine for heat treatment, and the resin of the sound insulation layer 103 is fully activated through a preheating furnace to enhance the bonding strength. Then the inner layer 101, the outer layer 102 and the sound insulation layer 103 are compounded together through a thermal compounding machine. Use a curing furnace to make the sound insulation layer 103 undergo a cross-linking reaction to ensure the bonding performance of the product. Then carry out online straightening, and finally enter a cooling machine for cooling to complete the preparation of the end cover 10.

[0064] The present application also provides a vehicle, including the motor controller as described above. The vehicle model is a heavy truck.

[0065] In the motor controller and the vehicle of the present application, by designing the end cover 10 as a three-layer composite structure and setting the middle sound insulation layer 103 as a damping material with strong sound insulation effect, the resonance of the end cover 10 is effectively suppressed, and the NVH performance of the motor controller is improved. By providing a strengthening portion 11 on the end cover 10, the structural strength and stiffness of the motor controller are improved, so that the motor controller can meet the performance requirements such as mode and strength. At the same time, the first strengthening portion 111 is arranged along the length direction of the end cover 10, so that the force on the end cover 10 is more uniform and it is convenient for production and manufacturing.

[0066] It should be noted that the technical solutions or technical features described in the above embodiments can be combined or supplemented with each other without conflict. The scope of protection of the present application is not limited to the precise structures described in the above embodiments and shown in the drawings; all modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present application shall be included within the scope of protection of the present application.

Claims

1. A motor controller, characterized in that, It includes an end cover and a lower shell assembled below the end cover, the end cover includes an inner layer, an outer layer and a silent layer located between the inner layer and the outer layer, and the silent layer is a damping material; a reinforcement part is provided on the end cover, and the reinforcement part includes a first reinforcement part located in the middle of the end cover and second reinforcement parts arranged on both sides of the first reinforcement part, and the first reinforcement part is arranged along the length direction of the end cover.

2. The motor controller according to claim 1, characterized in that The reinforcing parts are symmetrically arranged; the second reinforcing part is arranged along the width direction of the end cover; and the first reinforcing part and the second reinforcing part are connected in a circular arc transition.

3. The motor controller according to claim 2, characterized in that: The length of the first reinforcement portion is 300 mm to 350 mm, and the width of the first reinforcement portion is 50 mm to 70 mm; the length of the second reinforcement portion is 150 mm to 200 mm, and the width of the second reinforcement portion is 80 mm to 100 mm.

4. The motor controller according to claim 1, characterized in that, The end cover is provided with a plurality of mounting holes and positioning holes, and the aperture of the positioning holes is smaller than the aperture of the mounting holes.

5. The motor controller according to claim 4, characterized in that The end cover has a first side and a second side located on both sides of the length direction and a third side and a fourth side located on both sides of the width direction. A plurality of mounting holes are arranged at intervals on the first side, the second side, the third side and the fourth side.

6. The motor controller according to claim 5, characterized in that: The positioning hole includes a first positioning hole and a second positioning hole. The first positioning hole is arranged between the two mounting holes on the first side, and the second positioning hole is arranged at one end of the second side.

7. The motor controller according to claim 1, wherein The length of the end cover is 450 mm to 500 mm; the width of the end cover is 250 mm to 350 mm; and the thickness of the end cover is 1.2 mm.

8. The motor controller according to claim 1, wherein: The inner layer and the outer layer are both steel plates, and the sound-proof layer is bonded to the inner layer and the outer layer respectively; the tensile strength of the end cover is ≥290 MPa; and the elongation of the end cover is ≥40%.

9. The motor controller according to claim 1, wherein The materials of the noise-removing layer include resins, rubbers, antioxidants, lubricants and cross-linking agents.

10. A vehicle, characterized in that, The motor controller comprises the motor controller according to any one of claims 1 to 9.

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