Motor controller and vehicle

Abstract

The utility model relates to a motor controller and a vehicle, the motor controller comprises a shell, a capacitor and a power module, the shell is provided with a first installation cavity used for installing the power module and a second installation cavity used for installing the capacitor, the power module is connected with the capacitor through a support, and the capacitor is connected with the first installation cavity. A mounting groove is formed in the position, corresponding to the support, of the shell, and at least part of the support is fixed in the mounting groove in a potting mode. Through the arrangement, the bracket can be fixed on the shell without additionally arranging a mounting structure of the bracket, so that the assembling complexity of the bracket is reduced, and the mounting space is saved.

Description

Technical Field

[0001] The present application relates to the technical field of motor control devices, and in particular to a motor controller and a vehicle. Background Art

[0002] As a key structure of new energy vehicles, the motor controller can convert the electrical energy stored in the power battery into the electrical energy required to drive the motor according to instructions such as gear position, throttle, and brake, thereby controlling the starting, running, forward and backward speed, climbing strength and other driving conditions of the electric vehicle.

[0003] A motor controller typically includes a housing, a capacitor, and a power module. Both the capacitor and the power module are located within the housing and electrically connected to the power module. Currently, the bracket connecting the capacitor is typically secured to the housing via a mounting structure. This structure occupies a significant amount of installation space and complicates bracket installation. Utility Model Content

[0004] Based on this, it is necessary to provide a motor controller that is easy to assemble with a bracket and saves installation space.

[0005] The present application provides a motor controller, which includes a housing, a capacitor and a power module. The housing is provided with a first mounting cavity for mounting the power module and a second mounting cavity for mounting the capacitor. The power module is connected to the capacitor via a bracket. The housing is provided with a mounting groove at a position corresponding to the bracket. At least a portion of the bracket is fixed in the mounting groove by potting.

[0006] In one embodiment, at least a portion of the capacitor is fixed in the second mounting cavity by potting.

[0007] It can be understood that the shell is a part of the capacitor housing, which has a high degree of integration and does not require a separate capacitor housing and mounting structure, thereby reducing the complexity of additional installation and saving installation space.

[0008] In one embodiment, there are at least two first installation cavities, which are arranged side by side and spaced apart along the first direction, and the second installation cavity is located between two adjacent first installation cavities.

[0009] In one embodiment, there are two mounting slots, which are arranged side by side and spaced apart along the first direction. There are two first mounting cavities, two mounting slots are located between the two first mounting cavities, and the second mounting cavity is located between the two mounting slots.

[0010] In one embodiment, the housing is formed with a water flow channel extending along the first direction, and at least two of the first installation cavities are connected to the water flow channel.

[0011] It is understandable that at least two power modules share one water flow channel, and the water flow channel can dissipate heat for at least two power modules at the same time, reducing the complexity of opening additional water flow channels.

[0012] In one embodiment, the water flow channel is located below the first installation cavity, and part of the water flow channel is located below the second installation cavity.

[0013] It's understandable that the water channel passing under the capacitor simultaneously dissipates heat from the capacitor, preventing it from overheating internally, resolving the issue of high temperatures and reducing energy consumption. Furthermore, the capacitor is secured within the second mounting cavity using a potting method, keeping it close to the housing and further reducing heat buildup.

[0014] In one embodiment, both ends of the water flow channel are open, and blocking members for opening and closing the openings are provided at the openings.

[0015] In one embodiment, the power module includes a first copper bar, the capacitor includes a second copper bar, the first copper bar and the second copper bar are arranged side by side in the up and down direction, and the first copper bar, the second copper bar and the bracket have corresponding connection holes for part of the connector to pass through.

[0016] In one embodiment, the power module extends along the second direction, the first direction and the second direction are located in the same plane and both intersect with the vertical direction, the plane where the first direction and the second direction are located is defined as the first plane, and the power module is arranged along the first plane.

[0017] In one embodiment, the inner bottom wall of the shell is recessed downward to form the first installation cavity, and the second installation cavity is formed by the bottom wall of the shell protruding downward, with the opening of the second installation cavity facing upward.

[0018] In one embodiment, the capacitor is integrated with a transfer copper busbar for electrically connecting to a DC charger, a DC converter and an on-board charger.

[0019] The present application also provides a vehicle, which includes the motor controller described in any one of the above embodiments.

[0020] Compared with the prior art, in the motor controller provided in the present application, the power module is connected to the capacitor through a bracket, and the shell is provided with a mounting groove at the position corresponding to the bracket. The bracket is fixed in the mounting groove by potting, that is, the bracket can be fixed to the shell without setting up an additional bracket mounting structure, which reduces the complexity of the bracket assembly and saves installation space. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the conventional technology, the following briefly introduces the drawings required for use in the embodiments or the conventional technology descriptions. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0022] Figure 1 A three-dimensional diagram of a partial structure of a motor controller according to an embodiment of the present application;

[0023] Figure 2 for Figure 1 A schematic structural diagram of a housing of a motor controller is shown;

[0024] Figure 3 for Figure 1 A cross-sectional view of a motor controller is shown;

[0025] Figure 4 for Figure 3 A partial enlarged view of position I in the motor controller shown;

[0026] Figure 5 for Figure 1 A cross-sectional view of the motor controller shown in an exploded state;

[0027] Figure 6 for Figure 5 A local enlarged view of II in the motor controller is shown.

[0028] Figure numerals: 1. Shell; 11. First installation cavity; 111. Communication port; 12. Second installation cavity; 13. Installation slot; 14. Water flow channel; 2. Capacitor; 21. Second copper busbar; 22. Transfer copper busbar; 3. Power module; 31. First copper busbar; 4. Bracket; 5. Sealing piece; 6. Connection hole. DETAILED DESCRIPTION

[0029] To make the above-mentioned objects, features, and advantages of the present application more clearly understood, the specific embodiments of the present application are described in detail below with reference to the accompanying drawings. The following description sets forth many specific details to facilitate a full understanding of the present application. However, the present application can be implemented in many other ways than those described herein, and those skilled in the art can make similar improvements without violating the scope of the present application. Therefore, the present application is not limited to the specific embodiments disclosed below.

[0030] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it may be directly on the other component or there may also be a central component. When a component is considered to be "connected to" another component, it may be directly connected to the other component or there may be a central component at the same time. The terms "vertical", "horizontal", "up", "down", "left", "right", "side", "top", "bottom" and similar expressions used in the specification of this application are only used to describe the various example structural parts and elements of this application, but these terms are used here for the purpose of convenience of explanation and are determined based on the example orientations shown in the accompanying drawings, and do not represent the only implementation method. Since the embodiments disclosed in the application can be set in different directions, these terms indicating directions are only for illustration and should not be regarded as limitations. For example, "up" and "down" are not necessarily limited to directions opposite to or consistent with the direction of gravity.

[0031] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of such features. Throughout the description of this application, "plurality" means at least two, for example, two, three, etc., unless otherwise specifically defined.

[0032] In this application, unless otherwise expressly specified or limited, when a first feature is "above" or "below" a second feature, it can mean that the first feature is directly in contact with the second feature, or the first feature and the second feature are indirectly in contact through an intermediary. Furthermore, when a first feature is "above," "above," or "above" a second feature, it can mean that the first feature is directly above or diagonally above the second feature, or simply means that the first feature is higher in level than the second feature. When a first feature is "below," "below," or "below" a second feature, it can mean that the first feature is directly below or diagonally below the second feature, or simply means that the first feature is lower in level than the second feature.

[0033] Unless otherwise defined, all technical and scientific terms used in the specification of this application have the same meaning as commonly understood by those skilled in the art to which this application belongs. The terms used in the specification of this application are only for the purpose of describing specific embodiments and are not intended to limit this application. The term "and / or" used in the specification of this application includes any and all combinations of one or more of the relevant listed items.

[0034] See also Figures 1 to 6 The present application provides a motor controller. The motor controller includes a housing 1, a capacitor 2, and a power module 3 electrically connected to the capacitor 2. The housing 1 is provided with a first mounting cavity 11 for mounting the power module 3 and a second mounting cavity 12 for mounting the capacitor 2.

[0035] In one embodiment, if Figure 2 and Figure 5 As shown, the inner bottom wall of the housing 1 is recessed downward to form the first mounting cavity 11 and the second mounting cavity 12. In another embodiment, the bottom wall of the housing 1 protrudes downward to form the first mounting cavity 11 and the second mounting cavity 12, both of which have upward-facing openings. In this embodiment, the inner bottom wall of the housing 1 is recessed downward to form the first mounting cavity 11, and the second mounting cavity 12 is formed by the bottom wall of the housing 1 protruding downward, with the opening of the second mounting cavity 12 facing upward.

[0036] In this embodiment, capacitor 2 is fixed within second mounting cavity 12 by potting. Second mounting cavity 12 thus serves as a potting groove for capacitor 2. It will be appreciated that housing 1 is part of the outer shell of capacitor 2, resulting in a high degree of integration. This eliminates the need for a separate capacitor housing and mounting structure, reduces installation complexity, and saves installation space.

[0037] like Figures 3 to 6 As shown, the power module 3 is connected to the capacitor 2 via a bracket 4. The housing 1 is provided with a mounting groove 13 for mounting the bracket 4 at a position corresponding to the bracket 4. The bracket 4 is fixed in the mounting groove 13 by potting.

[0038] It is understandable that there is no need to provide an additional mounting structure for the bracket 4 , which reduces the complexity of assembling the bracket 4 and saves installation space.

[0039] like Figure 4 and Figure 6 As shown, the power module 3 includes a first copper busbar 31, and the capacitor 2 includes a second copper busbar 21. The first copper busbar 31 and the second copper busbar 21 are arranged side by side in the vertical direction. The first copper busbar 31, the second copper busbar 21, and the bracket 4 each have corresponding connection holes 6 through which the connector portion is inserted. In this way, the first copper busbar 31 and the second copper busbar 21 can be locked to the bracket 4 using the connector. The connector can be a bolt or screw.

[0040] It can be understood that the bracket 4 serves as a connecting frame for connecting the capacitor 2 and the power module 3 .

[0041] like Figure 1 and Figure 3 As shown, the bracket 4 extends along the second direction B. The first direction A and the second direction B are located in the same plane and intersect the vertical direction. There are at least two groups of the first copper bars 31 and the second copper bars 21, which are spaced apart along the second direction B. In one embodiment, there are two or more groups of the first copper bars 31 and the second copper bars 21. In this embodiment, there are six groups of the first copper bars 31 and the second copper bars 21.

[0042] There are at least two first installation cavities 11, spaced side by side along the first direction A. In one embodiment, there are more than two first installation cavities 11. The second installation cavity 12 is located between two adjacent first installation cavities 11; alternatively, the second installation cavity 12 is located to the side of the first installation cavity 11. The housing 1 is formed with a water flow channel 14 extending along the first direction A, and at least two first installation cavities 11 are connected to the water flow channel 14.

[0043] In this embodiment, if Figures 1 to 4 As shown, there are two first installation cavities 11. The water flow channel 14 is located below the first installation cavities 11, and both first installation cavities 11 are connected to the water flow channel 14. Specifically, the bottom wall of the first installation cavity 11 is provided with a communication port 111 that communicates with the water flow channel 14. The second installation cavity 12 is located between the two first installation cavities 11, and thus, part of the water flow channel 14 is located below the second installation cavity 12.

[0044] It is understood that at least two power modules 3 share a water flow channel 14, which can simultaneously dissipate heat from at least two power modules 3, reducing the complexity of providing additional water flow channels 14. Furthermore, the water flow channel 14 passes under the capacitor 2, dissipating heat from the capacitor 2 simultaneously, preventing excessive internal temperature rise, resolving the issue of high temperatures within the capacitor 2, and reducing energy consumption. Furthermore, the capacitor 2 is secured within the second mounting cavity 12 by potting, placing the capacitor 2 in close contact with the housing 1, further reducing heat buildup within the capacitor 2.

[0045] In addition, both ends of the water channel 14 are open, and sealing members 5 are installed at the openings to open and close them. It can be understood that after the sealing members 5 are installed, water can be stored in the water channel 14, thereby cooling the power module and capacitors, eliminating the need for external water pipes and saving costs.

[0046] In addition, in this embodiment, there are two mounting grooves 13 , which are arranged at intervals along the first direction A and located between the two first mounting cavities 11 , and the second mounting cavity 12 is located between the two mounting grooves 13 .

[0047] It is understood that the placement of the power module 3 in the first mounting cavity 11 can be selected based on actual needs. For a single-motor controller, the power module 3 can be placed in one of the first mounting cavities 11. For a dual-motor controller, the power modules 3 can be placed in both first mounting cavities 11. In this case, the two power modules 3 can share the same housing 1 and the same capacitor 2. That is, the two power modules 3 are connected to the capacitor 2 via the brackets 4 on the corresponding sides.

[0048] In this embodiment, each bracket 4 corresponds to 6 groups of first copper bars 31 and second copper bars 21 .

[0049] like Figure 1 、 Figure 3 and Figure 5 As shown, the power module 3 extends along the second direction B. The plane where the first direction A and the second direction B lie is defined as the first plane, and the power module 3 is arranged along the first plane, that is, the power module 3 is placed horizontally. In another embodiment, the power module 3 is arranged vertically.

[0050] like Figure 1 As shown, capacitor 2 is integrated with a copper busbar 22 for electrical connection to a DC charger, a DC converter, and an onboard charger. Capacitor 2 can then be electrically connected to the DC charger, the DC converter, and the onboard charger via copper busbar 22, which is located between the two brackets 4. It will be appreciated that copper busbar 22 is integrated with the capacitor to enable AC / DC charging and low-voltage power supply. The motor controller described above is used in a vehicle, i.e., the vehicle includes the motor controller.

[0051] The technical features of the above-mentioned embodiments can be combined arbitrarily. In order to make the description concise, not all possible combinations of the technical features in the above-mentioned embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0052] The above-described embodiments merely represent several implementation methods of the present application. While the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that a person of ordinary skill in the art may make various modifications and improvements without departing from the spirit of the present application, all of which fall within the scope of protection of the present application. Therefore, the scope of patent protection for the present application shall be determined by the appended claims.

Claims

1. A motor controller, characterized in that: The invention comprises a housing (1), a capacitor (2) and a power module (3); the housing (1) is provided with a first mounting cavity (11) for mounting the power module (3) and a second mounting cavity (12) for mounting the capacitor (2); the power module (3) is connected to the capacitor (2) via a bracket (4); the housing (1) is provided with a mounting groove (13) at a position corresponding to the bracket (4); at least a portion of the bracket (4) is fixed in the mounting groove (13) by potting.

2. The motor controller according to claim 1, characterized in that: At least a portion of the capacitor (2) is fixed in the second mounting cavity (12) by potting.

3. The motor controller according to claim 1, wherein: There are at least two first installation cavities (11), which are arranged side by side and spaced apart along a first direction (A), and the second installation cavity (12) is located between two adjacent first installation cavities (11).

4. The motor controller according to claim 3, characterized in that: There are two mounting grooves (13), which are arranged side by side and spaced apart along the first direction (A); there are two first mounting cavities (11); the two mounting grooves (13) are located between the two first mounting cavities (11); and the second mounting cavity (12) is located between the two mounting grooves (13).

5. The motor controller according to claim 3, characterized in that: The housing (1) is formed with a water flow channel (14) extending along the first direction (A), and at least two of the first installation cavities (11) are connected to the water flow channel (14).

6. The motor controller according to claim 5, characterized in that: The water flow channel (14) is located below the first installation cavity (11), and part of the water flow channel (14) is located below the second installation cavity (12).

7. The motor controller according to claim 5, characterized in that: Both ends of the water flow channel (14) are open, and blocking members (5) for opening and closing the openings are provided at the openings.

8. The motor controller according to claim 1, wherein: The power module (3) includes a first copper bar (31), and the capacitor (2) includes a second copper bar (21). The first copper bar (31) and the second copper bar (21) are arranged side by side in an up-down direction, and the first copper bar (31), the second copper bar (21) and the bracket (4) are provided with corresponding connection holes (6) for a portion of the connector to pass through.

9. The motor controller according to claim 3, characterized in that: The power module (3) extends along a second direction (B); the first direction (A) and the second direction (B) are located in the same plane and both intersect with the vertical direction; the plane in which the first direction (A) and the second direction (B) are located is defined as a first plane; and the power module (3) is arranged along the first plane.

10. The motor controller according to claim 1, wherein: The inner bottom wall of the shell (1) is recessed downward to form the first installation cavity (11), and the second installation cavity (12) is formed by the bottom wall of the shell (1) protruding downward, with the opening of the second installation cavity (12) facing upward.

11. The motor controller according to any one of claims 1 to 10, characterized in that: The capacitor (2) is integrated with a switching copper bus (22) for electrically connecting to a DC charger, a DC converter and an on-board charger.

12. A vehicle, characterized in that: The motor controller comprises the motor controller according to any one of claims 1 to 11.

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