Integrated plastic motor controller

Abstract

The utility model discloses an integrated plastic motor controller, which belongs to the technical field of motor controllers and comprises a shell. A high-voltage connecting part is arranged on the front side of the left end of the shell; the rear side of the left end of the shell is connected with a low-voltage connector pin; a low-voltage connector connecting part is formed on the outer side of the low-voltage connector pin on the shell; the housing is provided with a potting limiting assembly used for potting at the inner end of the high-voltage connecting part and the inner end of the low-voltage connector pin. A filter assembly and a capacitor assembly are encapsulated in the encapsulation limiting assembly, the filter assembly is welded with the capacitor assembly, and the filter assembly is welded with the high-voltage connecting part; and the shell is connected with a cooling channel for cooling the SIC power module on the right side of the encapsulation limiting assembly. By means of the mode, shielding plates are omitted through reasonable arrangement, supply chains are reduced, cost is reduced, and screws and other easily-invalid parts are omitted to the maximum extent.

Description

Technical Field

[0001] The utility model relates to the technical field of motor controllers, in particular to an integrated plastic motor controller. Background Art

[0002] The motor controller generally includes a controller housing and functional components arranged in the controller housing.

[0003] For example, CN108770323A discloses a motor controller, which includes a controller housing, in which a thin film capacitor assembly, an IGBT assembly, and a DC busbar are installed. A cooling base is installed at the bottom of the controller housing, and a capacitor cooling chamber, an IGBT cooling chamber, and a busbar cooling chamber are provided in the cooling base. The capacitor cooling chamber and the busbar cooling chamber are respectively arranged in a one-to-one correspondence with the positions of the thin film capacitor assembly and the DC busbar isolated above them. The bottom of the IGBT assembly is correspondingly inserted into the IGBT assembly cooling chamber. The motor controller disclosed in the present utility model has a controller housing designed and produced using a high-pressure aluminum alloy casting process, which is lightweight, compact, and has a high power density. The bottom of the housing adopts a full water cooling design to increase the heat exchange area and improve the heat exchange efficiency. A position-adjustable universal water pipe joint is installed on the controller housing, which reduces development costs and improves the adaptability of the product.

[0004] The aforementioned motor controllers are all metal assemblies, requiring dozens of complex parts to be assembled individually within a die-cast aluminum housing and sealed with a metal cover. Manufacturing involves numerous materials and processes, a long supply chain, and the assembly line requires more than a dozen workstations. The complex production process makes cost control difficult and product reliability low. To address high-voltage arcing, electrical isolation redundancy is required. Metal materials require electroplating to prevent oxidation and rust, and die-cast aluminum requires impregnation to prevent pinhole leaks throughout its lifecycle. The total product weight is typically 8-9 kg, with a volume of 7-8 liters.

[0005] Based on this, the utility model designs an integrated plastic motor controller to solve the above problems. Utility Model Content

[0006] In view of the above-mentioned shortcomings of the prior art, the utility model provides an integrated plastic motor controller.

[0007] In order to achieve the above objectives, the present invention is implemented through the following technical solutions:

[0008] An integrated plastic motor controller includes a housing:

[0009] A high-voltage connection portion is provided on the front side of the left end of the shell;

[0010] A low-voltage connector pin is connected to the rear side of the left end of the housing;

[0011] The housing is formed with a low-voltage connector connection portion outside the low-voltage connector pin;

[0012] The housing is provided with a potting limit assembly for potting at the inner end of the high-voltage connection part and the inner end of the low-voltage connector pin;

[0013] The filter component and the capacitor component are potted in the potting limit component, the filter component is welded to the capacitor component, and the filter component is welded to the high-voltage connection part;

[0014] The housing is connected to the right side of the potting limit assembly with a cooling channel for cooling the SIC power module;

[0015] The SIC power module is installed on the cooling channel, and the bottom of the SIC power module is in contact with the cooling channel and sealed;

[0016] The shell is embedded with an iron core on the right side of the cooling channel. An AC copper busbar is installed in the iron core, and the right end of the AC copper busbar is embedded in the shell.

[0017] The AC copper busbar is connected to the SIC power module by laser welding;

[0018] Multiple sets of limiting bushings are embedded on the outer edge of the shell;

[0019] The shell is integrally formed with a PCBA riveted support column inside the cavity, inside the potting limit assembly, and at the inner end of the low-voltage connector pin. There is a riveted column on the PCBA riveted support column. The top of the PCBA riveted support column is in contact with the driver board and control board two-in-one integrated circuit board. The driver board and control board two-in-one integrated circuit board is soldered to the low-voltage connector pin and the SIC power module pin through the PCBA welding vias, and the rivet column is hot-riveted to the PCBA fixing hole.

[0020] Furthermore, the high-voltage connection part includes a high-voltage connector connection part and a high-voltage connector copper busbar. The high-voltage connector copper busbar is located inside the high-voltage connector connection part. The high-voltage connector connection part and the shell are integrally formed. The inner end of the high-voltage connector copper busbar is located inside the shell. The inner end of the shell is welded to the filter assembly.

[0021] Furthermore, the potting limit assembly includes a first partition, a potting cavity, a second partition and a third partition. The first partition, the second partition and the third partition are integrally formed with the shell. The first partition is located at the inner end of the low-voltage connector pin, the second partition is located at the inner end of the high-voltage connector copper bus, and the third partition is located on the right side of the first partition. The inner bottom of the shell, the inner side wall of the first partition, the inner side wall of the second partition and the left side wall of the third partition are combined to form a potting cavity.

[0022] Furthermore, the filter assembly is installed on the left side of the potting cavity, and the capacitor assembly is installed on the right side of the potting cavity.

[0023] Furthermore, the cooling channel water pipe joint, the SIC module coolant sealing strip and the coolant flow groove are formed in the shell, the coolant flow groove is formed with water pipe joints connected to the through holes at the front and rear ends of the coolant flow groove, and the water pipe joint is integrally formed with the shell, and the SIC module coolant sealing strip is installed in the groove at the top of the coolant flow groove.

[0024] Furthermore, the bottom of the SIC power module is in contact with the top of the coolant flow groove and the top of the SIC module coolant sealing strip.

[0025] Furthermore, the shell is evenly embedded with first nuts on the left and right sides of the coolant flow groove.

[0026] Furthermore, the SIC power module is threadedly connected to the first nut through a screw.

[0027] Furthermore, a sealing strip for the shell joint surface is provided on the groove at the top of the shell. Beneficial effects

[0028] The utility model integrates the low-voltage connector pins, high-voltage connection part, potting limit assembly, cooling channel, iron core, AC copper busbar and limit bushing through injection molding, then pots the combined filter assembly and capacitor assembly, and then connects them to the high-voltage connection part. The SIC power module is installed on the cooling channel, and the SIC power module is then connected to the capacitor assembly and the iron core. Finally, the driver board and control board two-in-one integrated circuit board is installed on the PCBA riveted support column, and the driver board and control board two-in-one integrated circuit board is connected to the low-voltage connector pins and the SIC power module. The number of parts is greatly reduced, the manufacturing process is simplified, the reliability is significantly improved, the product weight, volume and cost are greatly reduced, and the logistics turnover and production manufacturing costs are greatly saved. The inherent insulation properties of the shell plastic completely eliminate the problems of high voltage arcing and breakdown. The shell will not rust, electrochemically corrode, and will not have internal pinholes. It can eliminate the redundant insulation design and eliminate the electroplating, impregnation and other processes. The driver board and control board are combined into one to form a two-in-one circuit board. The low-voltage connector pins are directly welded to the two-in-one circuit board, eliminating a pair of connectors and cables between the two circuits, and eliminating the connectors and cables between the two-in-one circuit board and the low-voltage connector. Reasonable layout eliminates the need for shielding plates, reduces the supply chain, reduces costs, and eliminates screws and other prone to failure parts as much as possible. Instead, an integrated riveting and welding process is used, which improves reliability by 30%, reduces the total weight by about 3Kg by 60%, reduces the volume by about 2.1L by 70%, reduces material and transportation costs by 30%, and reduces assembly and manufacturing costs by 60%. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be derived from these drawings without inventive effort.

[0030] Figure 1 This is a three-dimensional diagram of an integrated plastic motor controller of the present utility model;

[0031] Figure 2 This is a schematic diagram of the structure of the two-in-one circuit board of the present invention when it is not installed;

[0032] Figure 3 The shell of the utility model is shown as follows Figure 1 ;

[0033] Figure 4 The shell of the utility model is shown as follows Figure 2 ;

[0034] Figure 5 This is a schematic diagram of the capacitor assembly and its connection structure of the utility model;

[0035] Figure 6 This is a schematic diagram of the SIC power module of the present invention.

[0036] The numbers in the figure represent:

[0037] 301. Housing 302. First nut 303. Iron core 304. AC copper busbar 305. Water pipe connector 306. High-voltage connector copper busbar 307. High-voltage connector connection 308. Low-voltage connector pins 309. Housing joint sealing strip 310. SIC module coolant sealing strip 311. Sealing ring 312. Filter assembly 313. Capacitor assembly 314. SIC power module 315. SIC module DC input side solder joints 316. High-voltage connector and EMC filter Soldering points 317. SIC module AC output side soldering points 318. Low-voltage connector connection 319. PCBA riveted support columns 320. Driver board and control board two-in-one circuit board 321. SIC module wave soldering points 322. Two-in-one circuit board cold air riveting points 323. Low-voltage signal connector wave soldering points 324. Coolant flow groove 325. First partition 326. Potting cavity 327. Second partition 328. Third partition 329. Limit bushing 330. Riveted column. DETAILED DESCRIPTION

[0038] To make the purpose, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of protection of the present invention.

[0039] The present invention will be further described below with reference to the embodiments. Example

[0040] Please refer to the instruction manual Figure 1-6 , an integrated plastic motor controller, including an integrated plastic motor controller, including a housing 301:

[0041] A high voltage connection portion is provided on the front left end of the housing 301;

[0042] A low voltage connector pin 308 is connected to the rear side of the left end of the housing 301;

[0043] The housing 301 is formed with a low-voltage connector connection portion 318 outside the low-voltage connector pin 308;

[0044] The housing 301 is provided with a potting limit assembly for potting at the inner end of the high-voltage connection part and the inner end of the low-voltage connector pin 308;

[0045] The filter component 312 and the capacitor component 313 are encapsulated in the encapsulation limit component. The filter component 312 and the capacitor component 313 are welded, and the filter component 312 is welded to the high-voltage connection part.

[0046] The housing 301 is connected to a cooling channel for cooling the SIC power module 314 on the right side of the potting limit assembly;

[0047] The SIC power module 314 is installed on the cooling channel, and the bottom of the SIC power module 314 is in contact with the cooling channel and sealed;

[0048] The shell 301 is embedded with an iron core 303 on the right side of the cooling channel. An AC copper busbar 304 is installed in the iron core 303, and the right end of the AC copper busbar 304 is embedded in the shell 301.

[0049] The AC copper bus 304 is connected to the SIC power module 314 by laser welding;

[0050] Multiple sets of limiting bushings 329 are embedded in the outer edge of the housing 301;

[0051] The shell 301 is integrally formed with a PCBA riveted support column 319 inside the cavity, inside the potting limit assembly, and at the inner end of the low-voltage connector pin 308. There is a rivet column 330 on the PCBA riveted support column 319. The top of the PCBA riveted support column 319 is in contact with the driver board and control board two-in-one integrated circuit board 320. The driver board and control board two-in-one integrated circuit board 320 is soldered to the low-voltage connector pin 308 and the SIC power module 314 pin through the PCBA welding vias, and the rivet column 330 is hot-riveted to the PCBA fixing hole.

[0052] The low-voltage connector pin 308, the high-voltage connection part, the potting limit assembly, the cooling channel, the iron core 303, the AC copper bus 304 and the limit bushing 329 are integrally molded by injection molding, and then the combined filter assembly 312 and the capacitor assembly 313 are potted and then connected to the high-voltage connection part. The SIC power module 314 is installed on the cooling channel, and the SIC power module 314 is then connected to the capacitor assembly 313 and the AC copper bus 304. Finally, the drive board and control board two-in-one integrated circuit board 320 is installed on the PCBA riveted support column 319, and the drive board and control board two-in-one integrated circuit board 320 is connected to the low-voltage connector pin 308 and the SIC power module 314. The number of parts is greatly reduced, the manufacturing process is simplified, the reliability is significantly improved, the product weight, volume and cost are greatly reduced, and the logistics turnover and production manufacturing costs are greatly saved. The inherent insulating properties of the plastic in housing 301 completely eliminate high-voltage arcing and breakdown issues. Housing 301 is resistant to rust, electrochemical corrosion, and internal pinholes, eliminating redundant insulation design and processes such as electroplating and impregnation. The driver board and control board are combined into a two-in-one circuit board 320. The low-voltage connector pins 308 are directly soldered to the two-in-one circuit board 320, eliminating a pair of connectors and cables between the two circuits, as well as the connector and cables between the two-in-one circuit board 320 and the low-voltage connector. A rational layout eliminates the need for shielding plates, reduces supply chain complexity, and reduces costs. Screws and other prone-to-failure components are eliminated, replaced by an integrated riveting and welding process. This improves reliability by 30%, reduces the total weight by approximately 3 kg by 60%, and the volume by approximately 2.1 L by 70%. Material and transportation costs are reduced by 30%, and assembly and manufacturing costs are reduced by 60%.

[0053] The high-voltage connection portion includes a high-voltage connector connection portion 307 and a high-voltage connector copper busbar 306. The high-voltage connector copper busbar 306 is located within the high-voltage connector connection portion 307. The high-voltage connector connection portion 307 and the housing 301 are integrally formed. The inner end of the high-voltage connector copper busbar 306 is located within the housing 301. The inner end of the housing 301 is welded to the filter assembly 312.

[0054] The inner end of the high-voltage connector copper bar 306 is connected to the filter assembly 312 to form a high-voltage connector and EMC filter welding point 316;

[0055] The high-voltage connector connection part 307 of the high-voltage connection part is integrally formed with the housing 301 , the inner end of the high-voltage connector copper bar 306 is located inside the housing 301 , and the inner end of the housing 301 is embedded in the housing 301 ;

[0056] The potting limit assembly includes a first partition 325, a potting cavity 326, a second partition 327 and a third partition 328. The first partition 325, the second partition 327 and the third partition 328 are integrally formed with the shell 301. The first partition 325 is located at the inner end of the low-voltage connector pin 308, the second partition 327 is located at the inner end of the high-voltage connector copper bar 306, and the third partition 328 is located on the right side of the first partition 325. The bottom of the shell 301, the inner side wall of the first partition (325), the inner side wall of the second partition 327 and the left side wall of the third partition 328 are combined to form the potting cavity 326.

[0057] The filter assembly 312 is installed on the left side of the potting cavity 326, and the capacitor assembly 313 is installed on the right side of the potting cavity 326;

[0058] After the connection between the filter assembly 312 and the filter assembly 312 is welded, it is placed in the potting cavity 326 of the potting limit assembly, and then potting glue is poured into the potting cavity 326 to achieve the potting process of the filter assembly 312 and the capacitor assembly 313;

[0059] Cooling channel water pipe connector 305, SIC module coolant sealing strip 310 and coolant flow groove 324. The coolant flow groove 324 is formed in the housing 301. The water pipe connector 305 is connected to the through holes at the front and rear ends of the coolant flow groove 324. The water pipe connector 305 is integrally formed with the housing 301. The SIC module coolant sealing strip 310 is installed in the groove at the top of the coolant flow groove 324.

[0060] The connection between the SIC module coolant sealing strip 310 and the groove at the top of the coolant flow groove 324 is glue curing / pre-curing / bonding.

[0061] The bottom of the SIC power module 314 is in contact with the top of the coolant flow groove 324 and the top of the SIC module coolant sealing strip 310;

[0062] The housing 301 is evenly embedded with first nuts 302 on both sides of the coolant flow groove 324, and the SIC power module 314 is threadedly connected to the first nuts 302 by screws;

[0063] The SIC power module 314 is connected to the capacitor assembly 313, and the connection between the SIC power module 314 and the capacitor assembly 313 forms a SIC module DC input side welding point 315;

[0064] A sealing ring 311 is installed at the connection between the shell 301 and the right end of the AC copper bus 304

[0065] The connection between the SIC power module 314 and the AC copper busbar 304 forms a SIC module AC output side welding point 317;

[0066] A low-voltage signal connector wave soldering point 323 is formed at the connection between the two-in-one integrated circuit board 320 of the drive board and control board and the low-voltage connector pin 308. A two-in-one circuit board cold air riveting point 322 is formed at the connection between the two-in-one integrated circuit board 320 of the drive board and control board and the rivet column 330. The two-in-one integrated circuit board 320 of the drive board and control board and the SIC power module 314 pin form an SIC module wave soldering point 321, thereby supporting and fixing the top of the two-in-one integrated circuit board 320 of the drive board and control board. At the same time, the two-in-one integrated circuit board 320 of the drive board and control board is conveniently connected to the low-voltage connector pin 308 and the SIC power module 314.

[0067] A molding method for an integrated plastic motor controller comprises the following steps:

[0068] Step 1: Install the low-voltage connector pin 308, the high-voltage connector copper busbar 306, the iron core 303, the AC copper busbar 304, the limit bushing 329, the rivet column 330 and the first nut 302 into the injection mold, fill the injection mold with a high-temperature plastic solution, and form the shell 301 after cooling and solidification. The shell 301 is integrally formed with the high-voltage connection part, the potting limit assembly, the cooling channel, the low-voltage connector pin 308, the limit bushing 329, the iron core 303 and the AC copper busbar 304;

[0069] Step 2: Weld the adjacent copper bars of the filter assembly 312 and the capacitor assembly 313 on the outside, install the filter assembly 312 and the capacitor assembly 313 in the potting cavity 326, and fill the potting cavity 326 with potting glue;

[0070] Step 3: Install the SIC module coolant sealing strip 310 into the groove at the top of the coolant flow groove 324, and the housing joint surface sealing strip 309 into the groove at the top of the housing 301;

[0071] Step 4: Install the SIC power module 314 on the cooling channel with screws, laser weld the connection between the SIC power module 314, the AC copper bus 304, and the capacitor assembly 313, and laser weld the connection between the filter assembly 312 and the high-voltage connector copper bus 306;

[0072] Step 5: Install the two-in-one integrated circuit board 320 of the driver board and control board onto the PCBA riveted support column 319, and connect the riveted column 330 to the two-in-one integrated circuit board 320 of the driver board and control board by hot air riveting. Then, weld the two-in-one integrated circuit board 320 of the driver board and control board to the pins of the low-voltage connector 308 and the pins of the SIC power module 314 by wave soldering.

[0073] This process is very simple, involves few parts, and has very low logistics and manufacturing costs. Traditional fixed connections and seals are replaced with one-piece injection molding, and traditional high-voltage circuit bolt connections are replaced with laser welding, hot air riveting, and wave soldering, greatly improving product consistency and stability.

[0074] When in use, the shell 301 is aligned with the motor installation position, and the AC copper busbar 304 is plugged into the input end of the motor. The shell joint surface sealing strip 309 plays a role in sealing contact between the shell 301 and the motor. The screw is threadedly connected to the limit bushing 329, and the motor is threadedly connected to realize the integrated plastic motor controller and the motor quick connection installation. The high-voltage connector connection part 307 is plugged into the external high-voltage connector, and the high-voltage connector copper busbar 306 is electrically connected to the external high-voltage connector; the low-voltage connector connection part 318 and the low-voltage connector pin 308 are connected to the low-voltage connector.

[0075] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements will not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the various embodiments of the present invention.

Claims

1. An integrated plastic motor controller, comprising a housing (301), characterized in that: A high-voltage connection portion is provided on the front side of the left end of the housing (301); A low-voltage connector pin (308) is connected to the rear side of the left end of the housing (301); The housing (301) is formed with a low-voltage connector connecting portion (318) outside the low-voltage connector pin (308); The housing (301) is provided with a potting limit assembly for potting at the inner end of the high-voltage connection portion and the inner end of the low-voltage connector pin (308); A filter component (312) and a capacitor component (313) are encapsulated in the encapsulation limit component, the filter component (312) and the capacitor component (313) are welded, and the filter component (312) and the high-voltage connection portion are welded; The housing (301) is connected to a cooling channel for cooling the SIC power module (314) on the right side of the potting limit assembly; A SIC power module (314) is installed on the cooling channel, and the bottom of the SIC power module (314) is in contact with and sealed against the cooling channel; The shell (301) is embedded with an iron core (303) on the right side of the cooling channel, an AC copper busbar (304) is installed in the iron core (303), and the right end of the AC copper busbar (304) is embedded in the shell (301); The AC copper busbar (304) is connected to the SIC power module (314) by laser welding; Multiple groups of limiting bushings (329) are embedded on the outer edge of the shell (301); The housing (301) is integrally formed with a PCBA riveted support column (319) in the cavity, in the potting limit assembly, and at the inner end of the low-voltage connector pin (308). A riveted column (330) is provided on the PCBA riveted support column (319). The top of the PCBA riveted support column (319) is in contact with a two-in-one integrated circuit board (320) of a driving board and a control board. The two-in-one integrated circuit board (320) of the driving board and the control board is soldered to the low-voltage connector pin (308) and the SIC power module (314) pin through the PCBA welding vias, and the riveted column (330) is thermally riveted to the PCBA fixing hole.

2. The integrated plastic motor controller according to claim 1, characterized in that: The high-voltage connection portion comprises a high-voltage connector connection portion (307) and a high-voltage connector copper busbar (306); the high-voltage connector copper busbar (306) is located within the high-voltage connector connection portion (307); the high-voltage connector connection portion (307) and the housing (301) are integrally formed; the inner end of the high-voltage connector copper busbar (306) is located within the housing (301); and the inner end of the housing (301) is welded to the filter assembly (312).

3. The integrated plastic motor controller according to claim 2, characterized in that: The potting limit assembly includes a first partition (325), a potting cavity (326), a second partition (327) and a third partition (328). The first partition (325), the second partition (327) and the third partition (328) are integrally formed with the shell (301). The first partition (325) is located at the inner end of the low-voltage connector pin (308), the second partition (327) is located at the inner end of the high-voltage connector copper bar (306), and the third partition (328) is located on the right side of the first partition (325). The inner bottom of the shell (301), the inner side wall of the first partition (325), the inner side wall of the second partition (327) and the left side wall of the third partition (328) are combined to form the potting cavity (326).

4. The integrated plastic motor controller according to claim 3, characterized in that: The filter assembly (312) is installed on the left side of the potting cavity (326), and the capacitor assembly (313) is installed on the right side of the potting cavity (326).

5. The integrated plastic motor controller according to claim 4, characterized in that: A cooling channel water pipe joint (305), a SIC module coolant sealing strip (310) and a coolant flow groove (324), wherein the coolant flow groove (324) is formed in the shell (301), the water pipe joint (305) is connected to the through holes at the front and rear ends of the coolant flow groove (324), and the water pipe joint (305) and the shell (301) are integrally formed, and the SIC module coolant sealing strip (310) is installed in the groove at the top of the coolant flow groove (324).

6. The integrated plastic motor controller according to claim 5, characterized in that: The bottom of the SIC power module (314) is in contact with the top of the coolant flow groove (324) and the top of the SIC module coolant sealing strip (310).

7. The integrated plastic motor controller according to claim 6, characterized in that: The housing (301) is evenly embedded with first nuts (302) on the left and right sides of the coolant flow groove (324).

8. The integrated plastic motor controller according to claim 7, characterized in that: The SIC power module (314) is threadedly connected to the first nut (302) via a screw.

9. The integrated plastic motor controller according to claim 8, characterized in that: A housing joint surface sealing strip (309) is provided on the top groove of the housing (301).

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