Detection driving assembly and motor controller

Abstract

The utility model relates to a detection driving assembly and a motor controller, the motor controller comprises a driving board and a current sensor assembly, and the current sensor assembly is welded on the driving board and is electrically connected with the driving board. According to the motor controller, the current sensor assembly is directly arranged on the driving board and electrically connected with the driving board, a small current sampling board and a flat cable between the small current sampling board and the control board are omitted, signal transmission is carried out by means of the driving board, electric connection in the motor controller is simplified, occupied space is reduced, and cost is also saved.

Description

Technical Field

[0001] The present application relates to the technical field of motor control, and particularly to a detection drive assembly and a motor controller. Background Art

[0002] The motor controller of a new energy hybrid vehicle usually adopts a dual motor controller, which can control both the driving motor and the generating motor. In the dual motor controller, the three-phase currents of two motors need to be collected. Usually, 2 three-in-one current sensors are used (each current sensor contains 3 magnetic cores inside, collecting the three-phase currents of UVW, a total of 6 magnetic cores).

[0003] However, in the related art, the current sensor is welded on the current sampling small board, and the current sampling small board is then connected to the control board using a flexible cable. The current sampling signal is transmitted to the control board through the current sampling flexible cable. In addition, the drive board 1 and the drive board 2 of the controller are also connected to the control board through a flexible cable. Obviously, with this connection method of the controller, it is both complex and space-consuming. Summary of the Utility Model

[0004] Based on this, in view of the above problems, it is necessary to provide a detection drive assembly with a simple internal connection and space saving, and a motor controller having the detection drive assembly.

[0005] A detection drive assembly, the detection drive assembly includes:

[0006] A drive board; and

[0007] A current sensor assembly, which is welded on the drive board and electrically connected to the drive board.

[0008] In one embodiment, the current sensor assembly includes an injection molded body, multiple groups of sensor bodies, and multiple copper bars. All the sensor bodies and the copper bars are connected into one body through the injection molded body.

[0009] In one embodiment, each group of the sensor bodies includes a magnetic core and a detection chip. Each magnetic core and the detection chip are at least partially wrapped by the injection molded body. The copper bar includes an injection molded connection part and an electrical connection part. The injection molded connection part is wrapped by the injection molded body, and the electrical connection part is at least partially exposed.

[0010] In one embodiment, the magnetic core is configured such that its thickness direction is parallel to the thickness direction of the injection molded body.

[0011] In one embodiment, the current sensor assembly further includes a circuit board, and the detection chip is electrically connected to the circuit board; the circuit board, all the sensor bodies, and the copper busbar are connected into an integral body through the injection molded body, and signal pins are exposed on the circuit board, and the current sensor assembly is electrically connected to the drive board through the signal pins.

[0012] In one embodiment, the current sensor assembly includes at least two three-in-one sensors;

[0013] All the three-in-one sensors are welded to the drive board; and / or, the ranges of at least two of all the three-in-one sensors are different. In one embodiment, the drive board has an assembly groove, and at least a part of the current sensor assembly is embedded in the assembly groove.

[0014] In one embodiment, one of the current sensor assembly and the drive board has a first positioning structure protruding therefrom, and the other has a second positioning structure cooperating with the first positioning structure.

[0015] In one embodiment, the current sensor assembly is welded to the drive board.

[0016] In one embodiment, the detection and drive assembly includes at least two of the drive boards, and the current sensor assembly is connected to one of the drive boards;

[0017] and / or, the current sensor assembly has signal pins, and the current sensor assembly is electrically connected to the drive board through the signal pins.

[0018] A motor controller includes the above-mentioned detection and drive assembly.

[0019] In the above-mentioned detection and drive assembly and the motor controller, the current sensor assembly is directly disposed on the drive board and electrically connected to the drive board, eliminating the current sampling small board and the wiring between the current sampling small board and the control board, and instead using the drive board for signal transmission, which not only simplifies the electrical connection inside the motor controller, reduces the space occupation, but also saves costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In order to more clearly illustrate the technical solutions in the embodiments of the present application 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 drawings in the following description are only some embodiments of the present application. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0021] Figure 1This is a partial structural schematic diagram of the detection drive assembly in an embodiment of the present application.

[0022] Figure 2 It is Figure 1 a structural schematic diagram of the current sensor assembly in the shown detection drive assembly.

[0023] Figure 3 It is Figure 1 another-angle structural schematic diagram of the shown current sensor assembly.

[0024] Figure 4 It is Figure 1 yet another-angle structural schematic diagram of the shown current sensor assembly.

[0025] Explanation of reference numerals: 100, detection drive assembly; 10, drive board; 30, current sensor assembly; 31, injection molded body; 311, connection hole; 35, copper bar; 351, electrical connection part; 37, circuit board; 371, signal pin; 373, first positioning structure. Detailed implementation manners

[0026] To make the above objects, features, and advantages of the present application more obvious and understandable, the following will describe the detailed implementation manners of the present application with reference to the accompanying drawings. Many specific details are set forth in the following description to fully understand the present application. However, the present application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar improvements without departing from the connotation of the present application. Therefore, the present application is not limited by the specific embodiments disclosed below.

[0027] In the description of the present application, it should be understood that if there appear these terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., the orientation or positional relationship indicated by these terms is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present application 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 therefore cannot be understood as a limitation to the present application.

[0028] In addition, if the term "and / or" appears, "and / or" is merely a correlative relationship describing the associated objects, indicating that three relationships may exist. For example, A and / or B may represent three cases: A exists alone, A and B exist simultaneously, and B exists alone. Additionally, in this text, the character " / " generally indicates that the associated objects before and after are in an "or" relationship. If terms such as "first" and "second" appear, these terms are only used for descriptive purposes and should not be construed as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include at least one such feature. In the description of this application, if the term "plurality" appears, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0029] In this application, unless otherwise clearly specified and defined, if terms such as "installed", "connected", "joined", "fixed", etc. appear, these terms should be understood in a broad sense. For example, it may be a fixed connection, a detachable connection, or integrated; 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 communication inside two elements or the interaction relationship between two elements, unless otherwise clearly defined. For those of ordinary skill in the art, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0030] In this application, unless otherwise clearly specified and defined, if there is a description such as a first feature being "on" or "under" a second feature, the meaning may be that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. Moreover, the first feature being "above", "over", and "on top of" the second feature may mean that the first feature is directly above or obliquely above the second feature, or merely indicates that the first feature has a higher horizontal height than the second feature. The first feature being "under", "beneath", and "underneath" the second feature may be that the first feature is directly below or obliquely below the second feature, or merely indicates that the first feature has a lower horizontal height than the second feature.

[0031] It should be noted that if an element is referred to as "fixed to" or "disposed on" another element, it may be directly on the other element or there may also be an intermediate element. If an element is considered to be "connected" to another element, it may be directly connected to the other element or there may be an intermediate element at the same time. If so, the terms "vertical", "horizontal", "up", "down", "left", "right", and similar expressions used in this application are only for illustrative purposes and do not represent the only implementation.

[0032] Please refer to Figures 1 to 4, a detection drive assembly 100 provided by an embodiment of the present application includes a drive board 10 and a current sensor assembly 30. The current sensor assembly 30 is welded to the drive board 10 and electrically connected to the drive board 10.

[0033] The present application also provides a motor controller, which includes the above-mentioned detection drive assembly 100. The motor controller is used in the electric control system of a vehicle and can be specifically used in a new energy hybrid vehicle. The motor controller can control a drive motor and a generating motor. It can be understood that, to achieve its normal functions, the motor controller also includes a conventional housing, a control board, an IGBT module (not shown in the figure), etc. The drive board 10, the current sensor assembly 30, and the control board are all arranged in the housing. Among them, the control board is the control core of the motor controller. The main control board circuit may include a main chip circuit, a power supply chip circuit, a communication circuit, a decoder circuit, a storage chip circuit, a temperature acquisition circuit, a signal amplification circuit, a PWM output circuit, etc. The drive board 10 serves as an interface board between the motor and the controller. It is electrically connected to the controller through a cable and is responsible for converting the instructions issued by the controller into executable action signals, enabling the motor to operate according to the instructions. The current sensor assembly 30 is mainly used to detect the direct current bus and / or the alternating current three-phase current, and the IGBT module is used for energy conversion and transmission.

[0034] Based on the connection relationship between the drive board 10 and the control board, the current sensor assembly 30 of the detection drive assembly 100 is installed on the drive board 10 and electrically connected to the control board through the drive board 10, that is, the signals detected by it are transmitted to the control board by means of the drive board 10.

[0035] In the above-mentioned detection drive assembly 100, the current sensor assembly 30 is directly arranged on the drive board 10 and electrically connected to the drive board 10, eliminating the current sampling small board and the cable between the current sampling small board and the control board, and instead using the drive board 10 for signal transmission. This not only simplifies the internal electrical connection of the motor controller, reduces the space occupation, but also saves costs. In addition, in the motor controller, the IGBT is below the drive board 10, and the IGBT will lead out three-phase copper bars. Welding the current sensor assembly 30 on the drive board 10 can reduce the length of the three-phase copper bars. In contrast, the control board is usually above the drive board 10. If the current sensor assembly 30 is welded to the control board, the current sensor assembly 30 will be at a farther position from the IGBT, and the three-phase copper bars will be longer and need to be bent.

[0036] In some embodiments, the drive board 10 has an assembly groove (not shown in the figure), and at least part of the current sensor assembly 30 is embedded in the assembly groove.

[0037] In this way, the position of the current sensor assembly 30 is closer to the position of the drive board 10, and even at the same height as the drive board 10, which can reduce the length of the three-phase copper busbar. In addition, the assembly groove of the drive board 10 can also have a certain fixing effect on the current sensor assembly 30, improving the anti-vibration performance.

[0038] In some embodiments, the detection drive assembly 100 includes at least two drive boards 10, and the current sensor assembly 30 is connected to one of the drive boards 10.

[0039] The drive board 10 is correspondingly connected between the controlled motor and the control board. The current sensor assembly 30 only needs to be electrically connected to any one of the drive boards 10 to complete signal transmission. Taking the motor controller controlling two three-phase motors including a drive motor and a generating motor as an example, the detection drive assembly 100 includes two drive boards 10.

[0040] In this way, the current sensor assembly 30 can select the installation position as needed and perform signal transmission by means of the drive board 10 on which it is installed.

[0041] In some embodiments, the current sensor assembly 30 has a signal pin 371, and the current sensor assembly 30 is electrically connected to the drive board 10 through the signal pin 371.

[0042] The drive board 10 has a corresponding power connection part, and the power connection part cooperates with the signal pin 371 of the current sensor assembly 30 installed on the drive board 10, and can be a metal contact or an electrical connection hole 311 position, etc., which is not specifically limited here.

[0043] In this way, there is no need for a wire harness connection between the current sensor assembly 30 and the drive board 10, and the electrical connection can be directly achieved through the signal pin 371 of the current sensor assembly 30.

[0044] In some embodiments, the current sensor assembly 30 includes an injection molded body 31, multiple groups of sensor bodies (not shown in the figure), and multiple copper busbars 35. All the sensor bodies and copper busbars 35 are connected into one body through the injection molded body 31.

[0045] In other words, all the sensor bodies and copper busbars 35 are injection molded into one body, and the structure obtained by injection molding with injection molding material is the injection molded body 31.

[0046] The sensor body and copper busbar 35 are designed as an integrated whole, integrating multiple components through injection molding. This helps reduce the size of the current sensor assembly 30, improves space utilization, and facilitates direct installation of the current sensor assembly 30 onto the driver board 10. Furthermore, the reduced size of the current sensor assembly 30 allows for a smaller overall motor controller design, making it compatible with a wider range of vehicle models. Furthermore, the integrated design reduces the number of independent components, making the motor controller more resistant to vibration.

[0047] Specifically, each sensor assembly consists of a magnetic core and a detection chip. The magnetic core is positioned around the copper busbar 35 and has a notch. The detection chip is a Hall effect chip and is located in the notch. When current flows through the copper busbar 35, a magnetic field is generated around it. The magnetic core concentrates the magnetic flux along the core's path. The detection chip is placed in the notch, and the magnetic flux passes through the detection chip. The detection chip senses the magnitude of the magnetic field and outputs a corresponding voltage signal (this voltage signal represents the magnitude of the current flowing through the corresponding copper busbar 35).

[0048] Each set of sensor bodies is paired with a copper busbar 35, with a one-to-one correspondence between the two. The number of sensor bodies and copper busbars 35 is designed based on the number of motors controlled by the motor controller. For example, if the motor controller controls two three-phase motors, including a drive motor and a generator motor, each motor corresponds to three copper busbars 35 and three sets of sensor bodies, respectively used to collect the UV and W three-phase currents. Accordingly, the number of sensor bodies and copper busbars 35 is six. In this way, the six sensor bodies and copper busbars 35 are integrated into one, resulting in a six-in-one current sensor assembly 30.

[0049] Furthermore, each magnetic core and detection chip is at least partially wrapped by the injection molding body 31 , and the copper busbar 35 includes an injection molding connection portion and an electrical connection portion 351 . The injection molding connection portion is wrapped by the injection molding body 31 , and the electrical connection portion 351 is at least partially exposed.

[0050] It can be understood that the magnetic core, the detection chip and the copper bus 35 are at least partially wrapped and fixed by the injection molding body 31, wherein wrapping refers to the injection molding body 31 covering the surface of the wrapped object.

[0051] In this way, under the wrapping and fixation of the injection molding body 31, the magnetic core, the detection chip and the copper busbar 35 are stably connected and maintain a stable position. The electrical connection part 351 of the copper busbar 35 is at least partially not wrapped by the injection molding body 31 and is exposed to the outside to facilitate its electrical connection.

[0052] Furthermore, the magnetic core is configured such that its thickness direction is parallel to the thickness direction of the molded body 31 .

[0053] It can be understood that the thickness direction of the magnetic core and the injection molded body 31 is the direction with the smallest dimension among the three directions perpendicular to each other.

[0054] In this way, the thickness direction of the magnetic core is consistent with the thickness direction of the injection molded body 31, which helps to reduce the overall thickness of the current sensor assembly 30, shrink its volume, and reduce the demand for injection molding materials.

[0055] In some embodiments, the injection molded body 31 has a connection hole 311, and the current sensor assembly 30 is connected to the housing through the connection hole 311. Specifically, the current sensor assembly 30 can be connected to the housing through threaded parts, riveting parts, etc. passing through the connection hole 311.

[0056] In this way, in addition to being connected to the driving board 10, the current sensor assembly 30 also has a connection relationship with the housing, which can improve the assembly stability of the current sensor assembly 30 and enhance its anti-vibration ability.

[0057] In some embodiments, the current sensor assembly 30 further includes a circuit board 37, and the detection chip is electrically connected to the circuit board 37. The circuit board 37, all the sensor bodies, and the copper bar 35 are connected as a whole through the injection molded body 31, and the signal pins 371 are exposed on the circuit board 37.

[0058] It can be understood that the current sensor assembly 30 is injection molded as a whole, a part of the circuit board 37 is wrapped by the injection molded body 31, and the signal pins 371 are kept exposed, and all the detection parts can be connected to the same circuit board 37.

[0059] In this way, the detection signal of the detection chip can continue to be transmitted through the circuit board 37. At the same time, the signal pins 371 of the circuit board 37 also facilitate the connection between the current sensor assembly 30 and the driving board 10.

[0060] In some other embodiments, the current sensor group does not have a circuit board 37, but directly leads out the pins of the detection chip as the signal pins 371, which is not specifically limited here.

[0061] In some embodiments, the signal pins 371 of the current sensor assembly 30 are aligned with the power connection part on the driving board 10 and are welded together to weld the current sensor assembly 30 to the driving board 10 and simultaneously achieve the electrical connection between the two.

[0062] In this way, the current sensor assembly 30 can be connected to the driving board 10 in a simple and fast manner.

[0063] In another embodiment, the current sensor assembly 30 includes at least two three-in-one sensors (not shown in the figure), and all the three-in-one sensors are welded to the driving board 10.

[0064] Understandably, each three-in-one sensor corresponds to detecting the three-phase current information of one motor. Taking the motor controller controlling two three-phase motors including a driving motor and a generating motor as an example, the current sensor assembly 30 has two three-in-one sensors.

[0065] Thus, the three-in-one sensors are arranged on the driving board 10 and are respectively welded to the driving board 10 to correspondingly detect different motors.

[0066] In some embodiments, at least two of all the three-in-one sensors have different ranges. In other words, the current sensor assembly 30 includes at least two three-in-one sensors with different ranges.

[0067] Among them, the range of the three-in-one sensor can be, but is not limited to, 0 - 500A, 0 - 800A, or 0 - 1000A, etc., and no specific limitation is made here.

[0068] Since different three-in-one sensors can be used to measure the three-phase currents of different motors, therefore, using three-in-one sensors with different ranges can match different motors and make the measurement more accurate.

[0069] In some embodiments, one of the current sensor assembly 30 and the driving board 10 has a first positioning structure 373 protruding therefrom, and the other has a second positioning structure that cooperates with the first positioning structure 373.

[0070] Among them, the first positioning structure 373 and the second positioning structure can be multiple and correspond one by one. The first positioning structure 373 can be a positioning post, a positioning pin, a positioning buckle, etc., and the second structure can be a positioning hole, a positioning bayonet, etc., and no specific limitation is made here.

[0071] Thus, the current sensor assembly 30 and the driving board 10 complete their mutual positioning by means of the first positioning structure 373 and the second positioning structure, so as to perform accurate connection and fixing and electrical connection.

[0072] Specifically, the current sensor assembly 30 has positioning posts as the first positioning structure 373. The positioning posts can be specifically located on the surface of the circuit board 37 with signal pins 371, and there are two positioning posts arranged at intervals on the circuit board 37. The end edges of the positioning posts are chamfered. The driving board 10 has positioning holes as the second positioning structure.

[0073] Thus, when the positioning posts are aligned with the positioning holes, the signal pins 371 are also aligned with the power connection parts. After inserting the two positioning posts into the positioning holes, the positioning between the current sensor assembly 30 and the driving board 10 is completed and connection can be made.

[0074] The above-mentioned motor controller integrates the structure of the current sensor assembly 30, directly injecting and molding the sensor body and the copper bar 35 together to reduce the volume. Compared with the controller in the related technology, which has a length, width, and height of 265.5 mm, 43 mm, and 66 mm respectively after separately injecting and molding the copper bar and then assembling and connecting it to the sensor, with a volume of 753489 mm 3 , the length, width, and height of the motor controller can reach 213.9 mm, 32.5 mm, and 50.8 mm respectively, and the volume is 353149 mm 3 , and the volume is reduced by approximately 53%. After reducing the volume, the current sensor assembly 30 is more suitable for being directly welded to the drive board 10, eliminating the current sampling small board and the current sampling cable in the related technology. The current sampling signal is transmitted from the drive board 10 to the control board through the existing cable of the drive board 10, which not only saves space but also reduces costs. At the same time, the volume of the motor controller can be designed to be smaller, enabling it to adapt to more vehicle models. In addition, after the current sensor assembly 30 is injection-molded as a whole, during the assembly process, it changes from multiple original components to 1 component, making the assembly simpler, with lower costs and stronger vibration resistance.

[0075] The technical features of the above-described embodiments can be combined arbitrarily. For the sake of concise description, not all possible combinations of the technical features in the above-described embodiments are described. However, as long as there is no contradiction in the combination of these technical features, it should be considered as the scope described in this specification.

[0076] The above-described embodiments merely represent several implementation manners of the present application. Their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the patent application. It should be noted that for those of ordinary skill in the art, without departing from the concept of the present application, several modifications and improvements can still be made, and these all belong to the protection scope of the present application. Therefore, the protection scope of the patent of the present application shall be subject to the appended claims.

Claims

1. A detection drive assembly, characterized in that, The detection drive assembly includes: a drive board (10); and a current sensor assembly (30), which is welded to the drive board (10) and electrically connected to the drive board (10).

2. The detection drive assembly according to claim 1, wherein The current sensor assembly (30) includes an injection molded body (31), multiple groups of sensor bodies, and multiple copper bars (35). All the sensor bodies and the copper bars (35) are connected into one body through the injection molded body (31).

3. The detection drive assembly according to claim 2, wherein, Each group of the sensor bodies includes a magnetic core and a detection chip. Each magnetic core and the detection chip are at least partially wrapped by the injection molded body (31). The copper bar (35) includes an injection molded connection part and an electrical connection part (351). The injection molded connection part is wrapped by the injection molded body (31), and the electrical connection part (351) is at least partially exposed.

4. The detection drive assembly according to claim 3, wherein, The magnetic core is configured such that its thickness direction is parallel to the thickness direction of the injection molded body (31).

5. The detection drive assembly according to claim 3, characterized in that, The current sensor assembly (30) further includes a circuit board (37). The detection chip is electrically connected to the circuit board (37). The circuit board (37), all the sensor bodies, and the copper bars (35) are connected into one body through the injection molded body (31). The circuit board (37) has signal pins (371) that are exposed. The current sensor assembly (30) is electrically connected to the drive board (10) through the signal pins (371).

6. The detection drive assembly according to claim 1, wherein The current sensor assembly (30) includes at least two three-in-one sensors; All the three-in-one sensors are welded to the drive board (10); and / or, at least two of all the three-in-one sensors have different ranges.

7. The detection drive assembly according to claim 1, wherein, The drive board (10) has an assembly groove, and at least part of the current sensor assembly (30) is embedded in the assembly groove.

8. The detection drive assembly according to claim 1, characterized in that, One of the current sensor assembly (30) and the drive board (10) has a first positioning structure (373) that protrudes, and the other has a second positioning structure that cooperates with the first positioning structure (373).

9. The detection drive assembly according to claim 1, characterized in that, The current sensor assembly (30) has signal pins (371), and the current sensor assembly (30) is electrically connected to the drive board (10) through the signal pins (371).

10. The detection drive assembly according to claim 1, wherein, The detection drive assembly includes at least two of the drive boards (10), and the current sensor assembly (30) is connected to one of the drive boards (10).

11. A motor controller, characterized in that, Including the detection drive assembly according to any one of claims 1-9.

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