Motor controller
Through the dual-layer structure and a modular motor controller, electromagnetic interference and adaptability problems are solved, the safety and thermal stability of electrical connections are achieved, cost and complexity are reduced, and the needs of different motor models are adapted.
Patent Information
- Application Number
- CN202422206509.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-09
- Publication Date
- 2025-08-01
- Estimated Expiration
- 2034-09-09
AI Technical Summary
The existing new energy vehicle motor controller has a compact structure, resulting in serious electromagnetic interference, difficulty in testing of EMC, and inability to adapt to different models of motors, increasing development costs and cycles.
The controller housing adopts a double-layer structure, power modules are installed on the upper layer, bus capacitors are installed on the lower layer, and AC and DC are separated by junction boxes and insulating blocks. It provides single motor and dual motor junction boxes selection, combining a unified insulating block design and cooling waterway to achieve modular and flexible configuration.
Reduce electromagnetic interference, improve electrical connection safety and stability, reduce cost and maintenance complexity, enhance thermal stability, adapt to more motor models, and meet multifunctional needs.
Smart Images
Figure CN223181939U_ABST
Abstract
Description
Technical Field
[0001] This application belongs to the technical field of electrical equipment, and particularly relates to a motor controller. Background Art
[0002] With the development of new energy vehicles, the product development cycle of new energy vehicles is getting shorter and shorter, and the development cycle of components such as motor controllers that match them is also gradually shortening. In the development cycle of motor controllers, the design, processing, mold opening, and testing of structural parts account for the majority of the entire development cycle and development cost. At the same time, with the maturity of the software and hardware platform technologies of each motor controller manufacturer, the software and hardware only need to be appropriately adjusted according to customer needs in newly developed motor controllers, which leads to the development of motor controllers gradually being manifested as the development of structural parts.
[0003] In the development of structural parts, the overall structural layout of the motor controller is particularly important. Most of the existing structural layouts of new energy vehicle motor controllers arrange all components inside the motor controller housing, such as bus capacitors, IGBT modules, copper bars, main control boards, etc.
[0004] Due to the compact structure of the motor controller, various devices need to be arranged in the same cavity, such as DC-AC, high-voltage and low-voltage devices, which often generate various electromagnetic interferences, thereby affecting the EMC test of the motor controller. To reduce interference, measures such as adding filter capacitors and magnetic rings are required to shield the interference. However, there are many uncertainties in the selection and finalization cycle of filter capacitors and magnetic rings, which not only increase costs but also extend the development cycle. At the same time, due to the compact structure, the motor controller often only fits customized models after design and finalization, and cannot fit other models, such as only fitting small-power dual motors or large-power single motors, etc. This leads to the need to re-develop the motor controller, increasing the development cost. Summary of the Invention
[0005] The purpose of this application is to provide a motor controller, which reduces electromagnetic interference and improves applicability through a controller housing with a double-layer structure and the selection of different types of junction boxes.
[0006] To achieve the above objective, the solution of this application is:
[0007] An embodiment of this application provides a motor controller, including a controller housing. The controller housing has an upper and a lower layer structure. A power module is installed on the upper layer of the controller housing, a bus capacitor is installed on the lower layer of the controller housing, and a junction box is installed between the power module and the bus capacitor. An insulating block is installed inside the junction box.
[0008] According to the above method of the embodiment of this application, the following additional technical features may also be included:
[0009] Further, a retaining wall is provided inside the junction box.
[0010] Further, the insulating block includes a three-phase AC insulating block and a bus DC insulating block, and the three-phase AC insulating block and the bus DC insulating block are separated by a retaining wall.
[0011] Further, the junction box includes a single-motor junction box and a double-motor junction box.
[0012] Further, under the control of a single motor, the power module is power-matched with the single motor, and the type of the junction box is a single-motor junction box.
[0013] Further, under the control of a double motor, the power module is power-matched with the double motor, and the type of the junction box is a double-motor junction box.
[0014] Further, the three-phase AC insulating block and the bus DC insulating block have a unified basic module, which is compatible with single motors and double motors.
[0015] Further, the bus DC insulating block is compatible with two-way positive and negative bus interfaces.
[0016] Further, the three-phase AC insulating block is compatible with two-way motor UVW interfaces.
[0017] Further, it includes a heat dissipation water channel, which is closely arranged below the power module and / or above the bus capacitor.
[0018] By using a motor controller provided by an embodiment of the present application, compared with the prior art, the following beneficial technical effects are achieved:
[0019] In the embodiment of the present application, by adopting a controller housing with a double-layer structure, the power module is installed on the upper layer and the bus capacitor is installed on the lower layer, and by providing two options of a single-motor junction box and a double-motor junction box, a high degree of modularity and flexibility are achieved. This design enables the motor controller to be flexibly configured according to different motor types and power requirements, reducing costs and maintenance complexity.
[0020] The insulating block installed inside the junction box in the embodiment of the present application, and the separation of the three-phase AC insulating block and the bus DC insulating block by a retaining wall effectively prevent electrical faults and short circuits, improving the safety and stability of electrical connections. At the same time, the design of the insulating block and the junction box also takes into account electromagnetic compatibility, reducing the mutual interference between alternating current and direct current.
[0021] In the embodiment of the present application, a heat dissipation water channel is arranged below the power module and / or above the bus capacitor, which can effectively isolate and reduce heat transfer, improve the thermal stability and service life of the motor controller, and ensure the stable operation of the motor controller in a high-temperature environment.
[0022] The three-phase AC insulation block and the bus DC insulation block of the motor controller adopt a unified basic module design, enabling it to be compatible with the working environments of both single-motor and dual-motor simultaneously. This design not only reduces the types and quantities of components, lowers the manufacturing cost and complexity, but also improves the versatility of the motor controller, enabling it to meet more types of motor control requirements. Description of the Drawings
[0023] Figure 1 Fig. shows the structural schematic diagram of a motor controller during single-motor control according to an embodiment of the present application;
[0024] Figure 2 Fig. shows the structural schematic diagram of a motor controller during dual-motor control according to an embodiment of the present application;
[0025] Figure 3 (a) shows the overall structural schematic diagram of the three-phase AC insulation block of a dual-motor of a motor controller according to an embodiment of the present application;
[0026] Figure 3 (b) shows the top view of the three-phase AC insulation block of a dual-motor of a motor controller according to an embodiment of the present application;
[0027] Figure 4 (a) shows the overall structural schematic diagram of the bus DC insulation block of a dual-motor of a motor controller according to an embodiment of the present application;
[0028] Figure 4 (b) shows the top view of the bus DC insulation block of a dual-motor of a motor controller according to an embodiment of the present application.
[0029] Description of the Reference Numerals: 1. Power module; 2. Controller housing; 3. Three-phase AC insulation block; 4. Retaining wall; 41. Single-motor junction box; 42. Dual-motor junction box; 5. Bus DC insulation block; 6. Bus capacitor. Detailed Embodiments
[0030] To make the above objects, features, and advantages of the present application more apparent and understandable, the following will describe in detail the specific embodiments of the present application with reference to the drawings. It can be understood that the specific embodiments described herein are only used to explain the present application and are not intended to limit the present application. Additionally, it should be noted that for the sake of convenience of description, only the parts related to the present application are shown in the drawings rather than all the structures. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the scope of protection of the present application.
[0031] The term "comprising" and "having" in this application, as well as any variations thereof, are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that includes a series of steps or units is not limited to the listed steps or units, but may optionally further include steps or units not listed, or may optionally further include other steps or units inherent to these processes, methods, products, or devices.
[0032] Referring to "embodiment" in this application means that the specific features, structures, or characteristics described in connection with the embodiment may be included in at least one embodiment of this application. The appearance of this phrase at various positions in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment mutually exclusive with other embodiments. Those skilled in the art will explicitly and implicitly understand that the embodiments described in this application may be combined with other embodiments.
[0033] A motor controller is an electronic device used to control the speed, direction, and output power of a motor. It actively works to control the motor to operate in accordance with the set direction, speed, angle, and response time.
[0034] As Figure 1 shown, an embodiment of this application provides a motor controller, which includes a controller housing 2 with a double-layer structure. The housing is designed with an upper and a lower layer structure. The power module 1 is installed on the upper layer, and the bus capacitor 6 is installed on the lower layer. This layout is conducive to hierarchical heat management, reduces the cross-influence of heat, improves the overall heat dissipation efficiency, and enables the motor controller to have a larger space for arranging components, and can match more motors without changing the structure of the motor controller.
[0035] It further includes a junction box and an insulating block. In the embodiment of this application, a junction box is provided between the power module 1 and the bus capacitor 6, and an insulating block is installed inside to ensure the safety and stability of the electrical connection. The use of the insulating block can effectively prevent electrical faults and short circuits and protect the circuit system.
[0036] In the embodiment of this application, the insulating block is also separated by a retaining wall 4. A retaining wall 4 is designed inside the junction box for separating the three-phase AC insulating block 3 and the bus DC insulating block 5. The schematic diagrams of the three-phase AC insulating block 3 and the bus DC insulating block 5 are as Figure 3 and Figure 4 shown, where Figure 3 (a) and Figure 4 (a) are respectively the overall structure schematic diagrams of the three-phase AC insulating block and the bus DC insulating block, Figure 3 (b) and Figure 4 (b) are respectively the top views of the three-phase AC insulating block and the bus DC insulating block. This design avoids the mutual interference between alternating current and direct current and improves the electromagnetic compatibility of the system.
[0037] AsFigure 1 and Figure 2 As shown in Figure 1 and Figure 2 , to meet different power requirements, the embodiments of the present application provide two options: a single-motor junction box 41 and a dual-motor junction box 42. This modular design enables the controller to be flexibly configured according to actual needs, reducing costs and maintenance complexity.
[0038] In the single-motor control mode, the power module 1 matches the power of the single motor, and the single-motor junction box 41 is adopted; in the dual-motor control mode, the power module 1 matches the total power of the dual motors, and the dual-motor junction box 42 is adopted. This design ensures a perfect match between the motor controller and the motor, improving the overall performance.
[0039] The embodiments of the present application also consider the compatibility of the insulating blocks. The three-phase AC insulating block 3 and the bus DC insulating block 5 adopt a unified basic module design, enabling them to be compatible with the working environments of both single motors and dual motors. This design reduces the types and quantities of components, lowering manufacturing costs and complexity.
[0040] Specifically, the bus DC insulating block 5 can be compatible with two sets of positive and negative bus interfaces. This design makes the controller more flexible and convenient when it needs to connect multiple power sources or motors simultaneously; the three-phase AC insulating block 3 can be compatible with two sets of motor UVW interfaces, meaning that one controller can control two three-phase motors simultaneously, improving the versatility of the controller.
[0041] The embodiments of the present application are provided with heat dissipation channels below the power module 1 and / or above the bus capacitor 6. The design of the heat dissipation channels can effectively isolate and reduce heat transfer, improving the thermal stability and lifespan of the entire system.
[0042] In summary, the embodiments of the present application disclose a motor controller, which relates to the technical field of electrical equipment. It includes a controller housing 2 with an upper and a lower layer structure. The power module 1 is installed on the upper layer, and the bus capacitor 6 is installed on the lower layer. A junction box is installed between the power module 1 and the bus capacitor 6. Inside the junction box, there are a three-phase AC insulating block 3 and a bus DC insulating block 5 with a unified basic module separated by a retaining wall 4. The bus DC insulating block 5 is compatible with two sets of positive and negative bus interfaces, and the three-phase AC insulating block 3 is compatible with two sets of motor UVW interfaces; the junction box includes a single-motor junction box 41 and a dual-motor junction box 42; it also includes heat dissipation channels, which are closely arranged below the power module 1 and / or above the bus capacitor 6. By adopting the motor controller provided by the embodiments of the present application, a high degree of modularity and flexibility is achieved, reducing costs and maintenance complexity, reducing the mutual interference between alternating current and direct current, improving the thermal stability and lifespan of the motor controller, ensuring the stable operation of the motor controller in a high-temperature environment, and also improving the versatility of the motor controller, enabling it to meet more types of motor control requirements.
[0043] It should be noted that in this application, the terms "comprising", "including" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements not only includes those elements, but also includes other elements not explicitly listed, or further includes elements inherent to such process, method, article or device. Without further limitation, an element defined by the statement "comprising one..." does not exclude the existence of additional identical elements in the process, method, article or device comprising that element. In addition, it should be pointed out that the scope of the methods and devices in the embodiments of this application is not limited to performing functions in the order shown or discussed, and may also include performing functions in a substantially simultaneous manner or in the reverse order according to the functions involved. For example, the described methods may be performed in an order different from that described, and various steps may be added, omitted, or combined. Additionally, the features described with reference to certain examples may be combined in other examples.
[0044] The embodiments of the present application have been described above in conjunction with the accompanying drawings. However, the present application is not limited to the above specific embodiments. The above specific embodiments are merely illustrative and not restrictive. Under the inspiration of the present application, those of ordinary skill in the art can also make many forms without departing from the purpose of the present application and the scope protected by the claims, and all of them fall within the protection scope of the present application.
Claims
1. A motor controller, characterized in that, It includes a controller housing (2), the controller housing (2) has an upper and a lower layer structure, a power module (1) is installed on the upper layer of the controller housing (2), a bus capacitor (6) is installed on the lower layer of the controller housing (2), a junction box is installed between the power module (1) and the bus capacitor (6), and an insulating block is installed inside the junction box.
2. The motor controller according to claim 1, characterized in that A retaining wall (4) is provided inside the junction box.
3. The motor controller according to claim 2, characterized in that, The insulating block includes a three-phase AC insulating block (3) and a bus DC insulating block (5), and the three-phase AC insulating block (3) and the bus DC insulating block (5) are separated by the retaining wall (4).
4. A motor controller as claimed in claim 1, wherein The junction box includes a single-motor junction box (41) and a double-motor junction box (42).
5. The motor controller according to claim 4, wherein Under single-motor control, the power module (1) is power-matched with the single motor, and the type of the junction box is the single-motor junction box (41).
6. The motor controller according to claim 4, wherein Under double-motor control, the power module (1) is power-matched with the double motor, and the type of the junction box is the double-motor junction box (42).
7. The motor controller according to claim 3, wherein The three-phase AC insulating block (3) and the bus DC insulating block (5) have a unified basic module, which is compatible with single motors and double motors.
8. The motor controller according to claim 7, characterized in that, The bus DC insulating block (5) is compatible with two sets of positive and negative bus interfaces.
9. The motor controller according to claim 7, characterized in that, The three-phase AC insulating block (3) is compatible with two sets of motor UVW interfaces.
10. A motor controller as claimed in claim 1, wherein It includes a heat dissipation channel, and the heat dissipation channel is closely arranged below the power module (1) and / or above the bus capacitor (6).