Motor controller structure

Abstract

The utility model relates to a motor controller structure, which comprises a shell and a cover body which are connected with each other, a cooling assembly and a circuit assembly are arranged in the shell, the circuit assembly comprises an energy storage capacitor, a PCBA board, an active discharger and a power module unit used for converting direct current into alternating current, and the cooling assembly comprises a cooling channel; the cooling channel is fixed in the shell, a water cooling piece is integrated in the power module unit, the cooling channel is connected with the water cooling piece, the active discharger is fixed on the PCBA board, the PCBA board and the energy storage capacitor are located on the two sides of the power module unit, the PCBA board is located at the upper end of the cooling channel, and the energy storage capacitor is connected with the PCBA board and the power module unit. Compared with the prior art, the utility model has the advantages of high integration level, optimized structural layout of the controller and the like.

Description

Technical Field

[0001] The utility model relates to the field of controllers, in particular to a motor controller structure. Background Art

[0002] As a major component of electric vehicles, the quality and performance of motor controllers are directly related to the quality of electric vehicles. Conventional motor controllers are large in size, which will directly affect the size of electric vehicles and reduce the internal space of electric vehicles. As the market continues to change, people's requirements for product performance, quality, size, environment, etc. are constantly increasing.

[0003] The motor controllers currently used in new energy vehicles have too many components and low integration. They have disadvantages such as being too large, complex supply chain management and production assembly processes, difficult maintenance and repair, high manufacturing costs, and low overall power density.

[0004] Existing motor controllers for new energy vehicles are large in size and have limitations in cooling effect, EMC shielding protection, and discharge safety. The basic structural layout cannot fully meet the functional requirements of various aspects within a certain space, making it impossible to reduce the spatial layout of the motor controller on the vehicle, affecting the layout of the vehicle's power system. Utility Model Content

[0005] The purpose of the present invention is to provide a motor controller structure in order to overcome the defects of the prior art in that the structure and layout inside the controller are complex, the compatibility is poor, and the space occupied is large.

[0006] The purpose of the utility model can be achieved through the following technical solutions:

[0007] A motor controller structure includes a housing and a cover connected to each other. A cooling assembly and a circuit assembly are provided in the housing. The circuit assembly includes an energy storage capacitor, a PCBA board, an active discharger, and a power module unit for converting direct current into alternating current. The cooling assembly includes a cooling channel.

[0008] The cooling channel is fixed in the shell, a water-cooling component is integrated in the power module unit, the cooling channel is connected to the water-cooling component, the active discharger is fixed on the PCBA board, the PCBA board and the energy storage capacitor are located on both sides of the power module unit, the PCBA board is located at the upper end of the cooling channel, and the energy storage capacitor is respectively connected to the PCBA board and the power module unit.

[0009] Preferably, the circuit assembly further comprises a two-phase DC plug-in, a DC copper busbar, a three-phase copper busbar and a three-phase output plug-in;

[0010] The two-phase DC plug-in and the three-phase output plug-in are fixed on the outside of the shell. The two-phase DC plug-in is connected to the input end of the energy storage capacitor through a DC copper busbar. The output end of the energy storage capacitor is connected to the power module unit. The power module unit is connected to the three-phase output plug-in through a three-phase copper busbar.

[0011] Preferably, the circuit assembly further comprises a filter unit, the input end of the filter unit is connected to the two-phase DC plug-in, and the output end is connected to the input end of the energy storage capacitor through a DC copper busbar.

[0012] Preferably, the two-phase DC plug-in and the three-phase output plug-in are both fixed to the housing by screws, and sealing rings are provided at the connection positions between the two-phase DC plug-in and the three-phase output plug-in and the housing.

[0013] Preferably, the active discharger is welded and fixed on the PCBA board.

[0014] Preferably, the cooling assembly further includes a cooling water inlet and a cooling water outlet, both of which are fixed on the outside of the shell, the cooling water inlet is connected to the water inlet of the cooling channel, and the cooling water outlet is connected to the water outlet of the cooling channel.

[0015] Preferably, the motor controller further comprises a low-voltage signal connector, and the low-voltage signal connector is fixed on the outside of the housing.

[0016] Preferably, the motor controller further includes a waterproof breathable valve, which is fixed on the outside of the shell and communicates with the inside of the shell.

[0017] Preferably, the waterproof breathable valve is connected to the housing via a buckle, and a sealing ring is provided at the connection position between the waterproof breathable valve and the housing.

[0018] Preferably, the cover is fixed to the housing by screws, and a sealant is provided at the connection position between the cover and the housing.

[0019] Compared with the prior art, the utility model has the following advantages:

[0020] (1) In this solution, the current package inputs DC power to the energy storage capacitor, which stores energy and removes ripple current. The energy storage capacitor is connected in parallel with the main circuit and converts the DC input into AC output through the switch of the power module unit. The relay disconnects the control signal of the PCBA board and consumes the energy in the energy storage capacitor through the active discharger to achieve the safety function. Cooling water enters the controller from the cooling water inlet, passes through the cooling channel and the power module unit with integrated water cooling components, and flows out of the controller from the cooling water outlet, thereby cooling the entire controller.

[0021] By directly fixing the active discharger to the PCBA board, the use of intermediate components is reduced and the space they occupy is minimized. The energy storage capacitor and PCBA are fixed together in the shell, which further reduces the number and space of intermediate connecting parts, reduces the problem of insufficient assembly clearance caused by tolerance accumulation, improves the accuracy of the overall controller installation, and optimizes the layout of the vehicle power system.

[0022] (2) The output of the current packet DC generates noise on the DC bus, which has a certain impact on the storage and conversion of current. This solution sets up a filter unit between the two-phase DC connector and the energy storage capacitor to filter the noise on the DC bus and improve the quality and stability of the controller. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 A top view of the motor controller provided by the utility model;

[0024] Figure 2 This is a front view of the motor controller provided by the utility model;

[0025] In the figure: 1. Filter unit, 2. Two-phase DC connector, 3. Energy storage capacitor, 4. Low-voltage signal connector, 5. Cooling water inlet, 6. Waterproof breathable valve, 7. Cooling water outlet, 8. Three-phase output connector, 9. Three-phase copper busbar, 10. DC copper busbar, 11. Active discharger, 12. Housing, 13. Cooling channel, 14. PCBA board, 15. Power module unit, 16. Cover. DETAILED DESCRIPTION

[0026] 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 embodiments of the present invention, not all embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings herein can be arranged and designed in various different configurations.

[0027] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but rather merely represents selected embodiments of the present invention. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without creative effort are also within the scope of protection of the present invention.

[0028] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, it does not need to be further defined or explained in subsequent drawings.

[0029] In the description of the present invention, it should be noted that the terms "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, or are the orientation or position relationship in which the utility model product is usually placed when in use. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, they cannot be understood as a limitation on the present invention.

[0030] It should be noted that the terms "first" and "second" are used for descriptive purposes only and should not be understood to indicate or imply relative importance or implicitly specify the number of the technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of this application, "plurality" means two or more, unless otherwise specifically defined.

[0031] Furthermore, terms such as "horizontal" and "vertical" do not necessarily mean that a component must be absolutely horizontal or overhanging, but rather that it can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but rather that it can be slightly tilted.

[0032] Example 1

[0033] like Figure 1 and Figure 2 As shown, this embodiment provides a motor controller structure, including a housing 12 and a cover 13 connected to each other. A cooling assembly and a circuit assembly are provided in the housing 1. The circuit assembly includes an energy storage capacitor 3, a PCBA board 14, an active discharger 11, and a power module unit 15 for converting direct current into alternating current. The cooling assembly includes a cooling channel 13.

[0034] The cooling channel 13 is fixed in the shell 12, and a water-cooling component is integrated in the power module unit 15. The cooling channel 13 is connected to the water-cooling component. The active discharger 11 is fixed on the PCBA board 14. The PCBA board 14 and the energy storage capacitor 3 are located on both sides of the power module unit 15. The PCBA board 14 is located at the upper end of the cooling channel 13, and the energy storage capacitor 3 is respectively connected to the PCBA board 14 and the power module unit 15.

[0035] The current package inputs DC power to the energy storage capacitor, which stores energy and removes ripple current. Connected in parallel with the main circuit, the power module unit's switch converts the DC input into AC output. When the relay disconnects the control signal from the PCBA board, the energy in the energy storage capacitor is dissipated through the active discharger, achieving safety. Cooling water enters the controller through the cooling water inlet, passes through the cooling channels and the power module unit with integrated water cooling components, and flows out of the controller through the cooling water outlet, cooling the entire controller.

[0036] By directly fixing the active discharger to the PCBA board, the use of intermediate components is reduced and the space they occupy is minimized. The energy storage capacitor and PCBA are fixed together in the shell, which further reduces the number and space of intermediate connecting parts, reduces the problem of insufficient assembly clearance caused by tolerance accumulation, improves the accuracy of the overall controller installation, and optimizes the layout of the vehicle power system.

[0037] As a preferred embodiment, the circuit assembly further includes a two-phase DC plug-in 2, a DC copper busbar 10, a three-phase copper busbar 9 and a three-phase output plug-in 8;

[0038] The two-phase DC plug-in 2 and the three-phase output plug-in 8 are fixed to the outside of the housing 12. The two-phase DC plug-in 2 is connected to the input end of the energy storage capacitor 3 through the DC copper bus 10. The output end of the energy storage capacitor 3 is connected to the power module unit 15. The power module unit 15 is connected to the three-phase output plug-in 8 through the three-phase copper bus 9.

[0039] Furthermore, the circuit assembly further includes a filter unit 1 , the input end of the filter unit 1 is connected to the two-phase DC plug-in 2 , and the output end is connected to the input end of the energy storage capacitor 3 through a DC copper bus 10 .

[0040] Optionally, the two-phase DC plug-in 2 and the three-phase output plug-in 8 are both fixed to the housing 12 by screws, and sealing rings are provided at the connection positions between the two-phase DC plug-in 2 and the three-phase output plug-in 8 and the housing 12.

[0041] A filter unit is set between the two-phase DC connector and the energy storage capacitor to filter the noise on the DC bus and improve the quality and stability of the controller.

[0042] Furthermore, the active discharger 11 is welded and fixed on the PCBA board 14. This reduces the number of connecting parts required in the middle, reduces the occupied volume, and facilitates installation.

[0043] Specifically, the cooling assembly also includes a cooling water inlet 5 and a cooling water outlet 7, both of which are fixed on the outside of the shell 12, the cooling water inlet 5 is connected to the water inlet of the cooling channel 13, and the cooling water outlet 7 is connected to the water outlet of the cooling channel 13.

[0044] The motor controller also includes a low-voltage signal connector 4, which is fixed to the outside of the housing 12. The motor controller also includes a waterproof breathable valve 6, which is fixed to the outside of the housing 12 and communicates with the interior of the housing 12. The waterproof breathable valve 6 is connected to the housing 12 via a snap-fit, and a sealing ring is provided at the connection between the waterproof breathable valve 6 and the housing 12.

[0045] Optionally, the cover 13 is fixed to the housing 12 by screws, and a sealant is provided at the connection between the cover 12 and the housing 13. While the screw connection is convenient, the sealant further improves the reliability of the connection between the housing 12 and the cover 13 and the overall sealing.

[0046] In combination with the above preferred and specific implementations, the more specific working principle of the motor controller of the present utility model is as follows:

[0047] The motor controller is primarily comprised of two parts: the circuitry and the cooling water circuit. DC power from the battery pack enters the controller via a two-phase DC connector 2. It then passes through a filter unit 1 to filter out any noise on the DC bus. This power is then connected to a storage capacitor 3 via a DC busbar 10. This capacitor stores energy and removes ripple current, and is connected in parallel with the main circuit. The power module unit 15 switches the DC input into an AC output, which is then connected to a three-phase output connector 8 via a three-phase busbar 9 to deliver the AC power to the external motor.

[0048] After the relay is disconnected, the energy in the energy storage capacitor 3 is dissipated through the active discharger 11 via a control signal from the PCBA board 14, achieving safety. Cooling water enters the controller through the cooling water inlet 5, passes through the cooling channel 13 and the integrated water-cooled power module unit 15, and exits the controller through the cooling water outlet 7, thereby cooling the entire controller. This streamlined overall layout reduces the number of connections between the controller components, improves the controller's integration, further optimizes the motor controller layout, and significantly improves the overall vehicle powertrain layout.

[0049] The above describes in detail the preferred embodiments of the present invention. It should be understood that those skilled in the art can make numerous modifications and variations based on the concepts of the present invention without inventive effort. Therefore, any technical solutions that can be derived by those skilled in the art based on the concepts of the present invention through logical analysis, reasoning, or limited experimentation based on the existing technology should be within the scope of protection defined by the claims.

Claims

1. A motor controller structure, comprising a housing (12) and a cover (16) connected to each other, wherein a cooling component and a circuit component are provided in the housing (12), characterized in that: The circuit assembly includes an energy storage capacitor (3), a PCBA board (14), an active discharger (11), and a power module unit (15) for converting direct current into alternating current, and the cooling assembly includes a cooling channel (13); The cooling channel (13) is fixed in the housing (12), a water-cooling component is integrated in the power module unit (15), the cooling channel (13) is connected to the water-cooling component, the active discharger (11) is fixed on the PCBA board (14), the PCBA board (14) and the energy storage capacitor (3) are located on both sides of the power module unit (15), the PCBA board (14) is located at the upper end of the cooling channel (13), and the energy storage capacitor (3) is respectively connected to the PCBA board (14) and the power module unit (15).

2. A motor controller structure according to claim 1, characterized in that: The circuit assembly further comprises a two-phase DC plug-in (2), a DC copper busbar (10), a three-phase copper busbar (9) and a three-phase output plug-in (8); The two-phase DC plug-in (2) and the three-phase output plug-in (8) are fixed on the outside of the housing (12); the two-phase DC plug-in (2) is connected to the input end of the energy storage capacitor (3) via a DC copper busbar (10); the output end of the energy storage capacitor (3) is connected to a power module unit (15); and the power module unit (15) is connected to the three-phase output plug-in (8) via a three-phase copper busbar (9).

3. A motor controller structure according to claim 2, characterized in that: The circuit assembly further comprises a filter unit (1), the input end of the filter unit (1) being connected to a two-phase DC plug-in (2), and the output end being connected to the input end of an energy storage capacitor (3) via a DC copper busbar (10).

4. A motor controller structure according to claim 2, characterized in that: The two-phase DC plug-in (2) and the three-phase output plug-in (8) are both fixed to the housing (12) by screws, and sealing rings are provided at the connection positions between the two-phase DC plug-in (2) and the three-phase output plug-in (8) and the housing (12).

5. The motor controller structure according to claim 1, characterized in that: The active discharger (11) is welded and fixed on the PCBA board (14).

6. A motor controller structure according to claim 1, characterized in that: The cooling assembly further comprises a cooling water inlet (5) and a cooling water outlet (7), both of which are fixed on the outside of the shell (12), the cooling water inlet (5) being connected to the water inlet of the cooling channel (13), and the cooling water outlet (7) being connected to the water outlet of the cooling channel (13).

7. The motor controller structure according to claim 1, characterized in that: The motor controller further comprises a low-voltage signal connector (4), and the low-voltage signal connector (4) is fixed on the outside of the housing (12).

8. The motor controller structure according to claim 1, characterized in that: The motor controller further comprises a waterproof breathable valve (6), which is fixed on the outside of the housing (12) and communicates with the inside of the housing (12).

9. A motor controller structure according to claim 8, characterized in that: The waterproof breathable valve (6) is connected to the housing (12) via a snap fastener, and a sealing ring is provided at the connection position between the waterproof breathable valve (6) and the housing (12).

10. The motor controller structure according to claim 1, characterized in that: The cover (16) is fixed to the housing (12) by screws, and a sealant is provided at the connection position between the cover (16) and the housing (12).

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