Electric drive controller shell, electric drive controller assembly and vehicle

Abstract

The utility model discloses an electric drive controller housing, an electric drive controller assembly and a vehicle, the electric drive controller housing comprises a housing main body, and the housing main body comprises a first installation cavity used for installing a control assembly, a second installation cavity used for installing a power supply assembly and a cooling pipeline. The first mounting cavity is formed in the upper surface of the shell body, the second mounting cavity is formed in the lower surface of the shell body, and the cooling pipeline part is located in the first mounting cavity and the second mounting cavity. According to the utility model, the upper part and the lower part of the shell of the electric drive controller are respectively divided into the first mounting cavity and the second mounting cavity, so that the internal space of the electric drive controller is effectively utilized to respectively mount the control assembly and the power supply assembly, and the cooling pipeline is arranged to cool the first mounting cavity and the second mounting cavity at the same time; therefore, the overall heat dissipation efficiency is improved, and the safety is ensured on the premise that the electric drive controller is integrated with the power supply assembly.

Description

Technical Field

[0001] The utility model relates to the technical field of electric drive controllers, and in particular to an electric drive controller housing, an electric drive controller assembly and a vehicle. Background Art

[0002] With the rapid development of the new energy vehicle industry, the electric drive controller, as its core power component, has become an important indicator for measuring vehicle competitiveness. By integrating more functional modules into the electric drive controller, the vehicle can gain greater advantages in size, quality and cost.

[0003] However, existing electric drive controllers, after integrating other functional modules, simply stack them together, resulting in no significant improvement in space utilization. Furthermore, the integrated electric drive controllers suffer from severe heat dissipation issues. Existing electric drive controllers typically only incorporate heat dissipation structures for the IGBT (insulated gate bipolar transistor) modules, but lack effective heat dissipation structures for the other integrated functional modules, impacting the overall stability of the integrated electric drive controller.

[0004] In view of this, it is necessary to provide an electric drive controller that improves space utilization and heat dissipation performance. Utility Model Content

[0005] The purpose of the present utility model is to overcome the shortcomings of low space utilization and weak heat dissipation performance of electric drive controllers in the prior art, and to provide an electric drive controller housing, an electric drive controller assembly and a vehicle, wherein the electric drive controller housing separates the upper and lower parts of the electric drive controller housing into a first installation cavity and a second installation cavity, respectively, so as to more effectively utilize the internal space of the electric drive controller to install the control component and the power supply component respectively, and by setting a cooling pipe, cool the first installation cavity and the second installation cavity at the same time to improve the overall heat dissipation efficiency, and ensure the overall stability and safety of the electric drive controller when the power supply component is integrated into the electric drive controller.

[0006] The technical solution of the utility model provides an electric drive controller housing, comprising a housing body, wherein the housing body comprises a first mounting cavity for mounting a control component, a second mounting cavity for mounting a power supply component, and a cooling pipeline;

[0007] The first installation cavity is arranged on the upper surface of the shell body, the second installation cavity is arranged on the lower surface of the shell body, and the cooling pipeline is partially located in the first installation cavity and the second installation cavity.

[0008] In one of the optional technical solutions, the portion of the cooling pipeline located in the first installation cavity forms a first cooling part, the portion of the cooling pipeline located in the second installation cavity forms a second cooling part, and the first cooling part is connected to the second cooling part.

[0009] In one of the optional technical solutions, the first cooling portion includes a cooling groove with an upward notch, and a cooling liquid inlet and a cooling liquid outlet are respectively provided at both ends of the cooling groove.

[0010] In one of the optional technical solutions, the cooling groove is used to install an IGBT module, and the notch of the cooling groove is sealed by installing the IGBT module and a sealing ring.

[0011] In one of the optional technical solutions, the second cooling portion includes a cooling wall protruding downward, the interior of the cooling wall is hollowed out and communicated with the cooling pipeline.

[0012] In one of the optional technical solutions, the cooling wall is an overall U-shaped structure to divide the second installation cavity into three installation areas.

[0013] In one of the optional technical solutions, the water inlet of the cooling pipeline is opened on the side of the shell body and communicates with the second cooling part, and the water outlet of the cooling pipeline is opened on the lower surface of the shell body and communicates with the first cooling part.

[0014] In one of the optional technical solutions, the cooling pipeline further includes a third cooling part for cooling the MOS tube controlled by PCT (Process Control Technology), and the third cooling part is located between the water outlet and the first cooling part.

[0015] The technical solution of the present utility model provides an electric drive controller assembly, including any of the aforementioned electric drive controller housings, a control component and a power supply component, wherein the control component is installed on the first mounting cavity, and the power supply component is installed on the second mounting cavity.

[0016] The technical solution of the present utility model provides a vehicle, comprising a vehicle body and any of the aforementioned electric drive controller assemblies.

[0017] The above technical solution has the following beneficial effects:

[0018] The electric drive controller housing provided by the present invention provides a first mounting cavity and a second mounting cavity at the top and bottom, respectively, so that the control component and the power supply component can be integrated into the electric drive controller with the housing body as a partition, thereby more effectively utilizing the internal space of the electric drive controller and improving the operating stability of the control component and the power supply component. In the case where the first mounting cavity and the second mounting cavity are provided at the top and bottom of the housing body, respectively, no additional cooling device is required. Only by providing a cooling pipe that passes through the first mounting cavity and the second mounting cavity at the same time, the components in the first mounting cavity and the second mounting cavity are cooled simultaneously, thereby improving the overall heat dissipation efficiency and ensuring the stability and safety of the electric drive controller when the control component and the power supply component are integrated into the electric drive controller. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The disclosure of the present invention will become easier to understand with reference to the accompanying drawings. It should be understood that these drawings are for illustrative purposes only and are not intended to limit the scope of protection of the present invention. In the drawings:

[0020] Figure 1 A structural diagram of an electric drive controller housing provided in one embodiment of the present utility model;

[0021] Figure 2 A bottom structural diagram of an electric drive controller housing provided by an embodiment of the present utility model;

[0022] Figure 3 A top view of the electric drive controller housing provided by one embodiment of the present utility model;

[0023] Figure 4 A cross-sectional view of an electric drive controller housing provided by one embodiment of the present utility model;

[0024] Figure 5 This is an exploded view of the electric drive controller housing and cover provided in one embodiment of the present invention.

[0025] Reference numerals in the figures:

[0026] 1. Housing body; 11. First installation cavity; 12. Second installation cavity;

[0027] 2. Cooling pipeline; 21. First cooling part; 211. Cooling groove; 22. Second cooling part; 221. Cooling wall; 23. Third cooling part; 24. Water inlet; 25. Water outlet;

[0028] 3. Cover body. DETAILED DESCRIPTION

[0029] The following further describes specific embodiments of the present invention with reference to the accompanying drawings. Identical components are denoted by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to directions in the accompanying drawings, while the terms "inward" and "outward" refer to directions toward or away from the geometric center of a particular component, respectively.

[0030] In this utility model, unless otherwise specified or limited, the term "fixed" and the like should be understood in a broad sense. For example, "fixed" can mean fixed connection, detachable connection, or integration; it can mean mechanical connection or electrical connection; it can mean direct connection or indirect connection through an intermediate medium; it can mean internal communication between two elements or interaction between two elements, unless otherwise specified. For those skilled in the art, the specific meanings of the above terms in this utility model can be understood according to specific circumstances.

[0031] like Figure 1-5 As shown, an electric drive controller housing provided by an embodiment of the present invention includes a housing body 1 , the housing body 1 includes a first installation cavity 11 for installing a control component, a second installation cavity 12 for installing a power supply component, and a cooling pipe 2 .

[0032] The first installation cavity 11 is provided on the upper surface of the housing body 1 , the second installation cavity 12 is provided on the lower surface of the housing body 1 , and the cooling pipeline 2 is partially located in the first installation cavity 11 and the second installation cavity 12 .

[0033] The shell body 1 includes a substrate, and the IGBT module is installed on the substrate. The IGBT module is upward relative to the substrate. The periphery of the first installation position is provided with an outer wall extending upward, and the periphery of the second installation position is provided with an outer wall extending downward.

[0034] The electric drive controller is a crucial component of the electric drive system, responsible for regulating the flow and distribution of electrical energy to control mechanical movement. In electric vehicles, the electric drive controller, often also referred to as the drive motor controller or motor controller, is one of the key controllers in electric vehicles. The electric drive controller receives commands from the vehicle controller, such as torque messages, to control the speed and direction of the drive motor. By adjusting parameters such as the motor's current, voltage, and frequency, the motor rotates at the desired speed and direction, thereby achieving power output. During braking or deceleration, the kinetic energy generated by the drive motor can be converted into electrical energy and fed back to the battery pack to extend the electric vehicle's range.

[0035] It should be noted that in traditional electric drive controller assemblies, the power supply component is generally not located within the controller. Instead, it typically includes components such as an onboard charger, inverter, and compressor controller. This component is often independently designed within the vehicle, leaving a significant amount of underutilized space within the controller. This ineffective use of internal space limits the miniaturization and lightweighting of the controller assembly. Furthermore, the independent heat dissipation of each component not only increases system complexity and cost, but also makes it difficult to ensure heat dissipation efficiency and stability under high-power operation.

[0036] In particular, in the electric drive controller assembly that combines electronic control, motor, and differential subtraction, the electronic control part is particularly critical to the integrated design of the control components and power components. In existing designs, although the electric drive controller housing integrates functions such as load bearing, electromagnetic shielding, and cooling water channels, it often only provides targeted heat dissipation for key heat sources such as IGBT modules, while ignoring the heat dissipation requirements of power components (such as on-board chargers and current converters) and other control components. This results in low overall heat dissipation efficiency, only local heat dissipation inside the electric drive controller, and uneven overall heat dissipation. In addition, after integration, the control components and power components are both installed above the housing body 1, and the space below the housing body 1 is underutilized, further limiting the system's integration and performance improvement.

[0037] In traditional designs, the power supply assembly and electric drive controller may be installed separately, and the cooling system is often set up independently, resulting in a complex structure and low heat dissipation efficiency. Even if the power supply assembly is integrated into the electric drive controller, the cooling pipe 2 in the electric drive controller housing only cools the IGBT module and cannot effectively cool other components of the control assembly and the power supply assembly.

[0038] The embodiment of the present utility model provides a housing for an electric drive controller in an electric vehicle, which enables the control component and the power supply component to be relatively independently integrated into the electric drive controller by arranging a first mounting position and a second mounting position that are independent of each other at the top and bottom, respectively. Furthermore, a curved cooling pipe 2 is used to cool the control component and the power supply component simultaneously without adding an additional cooling pipe 2. The cooling pipe 2 cleverly shuttles between the two mounting cavities to achieve effective heat transfer and dissipation, and also achieves a compact layout of the components and efficient heat dissipation. Through the integrated mounting structure, space utilization is improved, the length of the wiring harness and the number of connection points are reduced, and at the same time, the structural design of the cooling pipe 2 improves the heat dissipation efficiency, ensuring the stable operation of the controller in a high-temperature environment.

[0039] Cooling fluid continuously flows through cooling line 2 to cool the control components and power components in the electric drive controller housing. The coolant can be water, deionized water, or an ethylene glycol aqueous solution. Other coolants can also be selected based on thermal conductivity, antifreeze properties, and chemical stability to meet cooling requirements.

[0040] To sum up, the electric drive controller housing provided by the embodiment of the present invention has a first installation cavity 11 and a second installation cavity 12 respectively arranged at the top and bottom, so that the control component and the power supply component can be integrated into the electric drive controller with the housing body 1 as a partition, so as to more effectively utilize the internal space of the electric drive controller and at the same time improve the operating stability of the control component and the power supply component.

[0041] When the first installation cavity 11 and the second installation cavity 12 are respectively provided above and below the shell body 1, no additional cooling device is added. Only a cooling pipe 2 passing through the first installation cavity 11 and the second installation cavity 12 is provided to achieve simultaneous cooling of the components in the first installation cavity 11 and the second installation cavity 12, so as to improve the overall heat dissipation efficiency and ensure the stability and safety of the electric drive controller when the electric drive controller integrates the control component and the power supply component.

[0042] In one embodiment, Figure 1 and Figure 3 As shown, the portion of the cooling pipe 2 located in the first installation cavity 11 forms a first cooling portion 21 , and the portion of the cooling pipe 2 located in the second installation cavity 12 forms a second cooling portion 22 . The first cooling portion 21 is connected to the second cooling portion 22 .

[0043] In this embodiment, cooling pipeline 2 forms a first cooling section 21 within the first mounting cavity 11, primarily cooling the control components. A second cooling section 22 is formed within the second mounting cavity 12, dissipating heat from the power supply components. These two sections are connected by a pipeline, forming a single, interconnected cooling pipeline 2. Zoned cooling improves heat dissipation uniformity within the electric drive controller housing and enhances overall cooling effectiveness by increasing the time the coolant remains within the housing.

[0044] As needed, the structures of the first cooling portion 21 and the second cooling portion 22 can be changed to adjust the cooling according to the heat dissipation requirements of different components.

[0045] In one embodiment, Figure 1 As shown, the first cooling portion 21 includes a cooling groove 211 with an upward notch, and a cooling liquid inlet and a cooling liquid outlet are respectively provided at both ends of the cooling groove 211.

[0046] Furthermore, the cooling groove 211 is used to install an IGBT module, and the notch of the cooling groove 211 is sealed by installing the IGBT module and a sealing ring.

[0047] In this embodiment, by setting the first cooling portion 21 for mounting the IGBT module as a cooling groove 211, the cooling groove 211 does not need additional sealing settings, and can be sealed by mounting the IGBT module and the sealing ring on the periphery to prevent the coolant from overflowing. Figure 3 As shown, a coolant inlet and a coolant outlet are provided at each end of the cooling groove 211, allowing coolant to enter the cooling groove 211. The coolant entering the cooling groove 211 from the coolant inlet has sufficient time to effectively cool the IGBT module located above the cooling groove 211 before being discharged from the coolant outlet. Preferably, the cooling groove 211 has a rectangular structure. The rectangular shape of the cooling groove 211 significantly increases the contact area between the coolant and the lower surface of the IGBT module, thereby improving cooling efficiency and ensuring effective cooling of key heat sources such as the IGBT module within the electric drive controller.

[0048] Depending on the needs, mechanical sealing methods such as welding and crimping can be used, or a combination of various sealing materials can be used to improve the sealing effect. The sealed structure can effectively prevent coolant leakage and ensure the normal operation of the electric drive controller.

[0049] In one embodiment, Figure 2 As shown, the second cooling portion 22 includes a cooling wall 221 protruding downward, and the interior of the cooling wall 221 is hollow and communicated with the cooling pipeline 2.

[0050] Furthermore, the cooling wall 221 is in a U-shaped structure as a whole, so as to divide the second installation cavity 12 into three installation areas.

[0051] In this embodiment, the cooling wall 221 has at least two bending portions, so that the overall travel path of the second cooling portion 22 is a U-shaped bending path, and the cooling wall 221 extends toward the second installation position. Figure 4 As shown, cooling wall 221 has a gap inside for coolant to flow through. After the second mounting cavity 12 is divided into three mounting areas, because at least one side of each mounting area is connected to cooling wall 221, the coolant flowing through cooling wall 221 can evenly cool the components of the power assembly in all three mounting areas, thereby ensuring that the power assembly will not suffer from cooling loss after being integrated into the electric drive controller.

[0052] Preferably, if Figure 5As shown, the upper end of the cooling wall 221 is opened, and a cover 3 is provided on the opening. The cover 3 is welded to the upper end opening of the cooling wall 221 by stir friction welding to cover the opening. Stir friction welding refers to the use of heat generated by friction between a high-speed rotating welding tool and a workpiece to partially melt the material to be welded. When the welding tool moves forward along the welding interface, the plasticized material flows from the front to the rear of the welding tool under the action of the rotating friction force of the welding tool, and forms a dense solid phase weld under the extrusion of the welding tool. The sealing of the cover 3 can be ensured by stir friction welding, and a high-voltage capacitor can also be set on the cover 3 to improve the heat dissipation efficiency of the high-voltage capacitor. It can be seen from this that the first cooling part 21 can also cool the device located in the second mounting position below it, and the second cooling part 22 can also cool the device located in the first mounting position above it.

[0053] In one embodiment, Figure 1 and Figure 2 As shown, the water inlet 24 of the cooling pipe 2 is opened on the side of the shell body 1 and communicates with the second cooling part 22 , and the water outlet 25 of the cooling pipe 2 is opened on the lower surface of the shell body 1 and communicates with the first cooling part 21 .

[0054] In this embodiment, the water inlet 24 is positioned at a higher level than the water outlet 25. After the coolant enters the cooling pipe 2 through the water inlet 24, it flows sequentially through the second cooling section 22 and the first cooling section 21 under the action of an external water pump, and then flows out through the water outlet 25, allowing the coolant to smoothly complete the cooling process. By providing the water inlet 24 on the side of the housing body 1 and the water outlet 25 on the lower surface of the housing body 1, the water pump can be assisted in better directing the flow of the coolant, thereby improving the cooling effect.

[0055] As needed, in addition to the layout of water inlet 24 and water outlet 25 on the side, the position and number of the water inlet 24 and the water outlet 25 can also be adjusted according to specific needs to achieve the best cooling effect.

[0056] In one embodiment, Figure 1 and Figure 3 As shown, the cooling pipeline 2 further includes a third cooling portion 23 for cooling the MOS tube controlled by the PCT. The third cooling portion 23 is located between the water outlet 25 and the first cooling portion 21 .

[0057] In this embodiment, the MOS tube controlled by the PCT is installed on the side of the first installation position. By adding a third cooling part 23 between the drain port and the first cooling part 21, the MOS tube controlled by the PCT can be specially cooled before the coolant is discharged, thereby maximizing the heat absorption capacity of the coolant in the entire cooling process, making space utilization and heat distribution more reasonable, and helping to improve the internal space utilization and heat dissipation stability of the integrated electric drive controller.

[0058] An embodiment of the present invention provides an electric drive controller assembly, including an electric drive controller housing, a control component, and a power supply component as provided in any of the aforementioned embodiments. The control component is installed in the first installation cavity 11, and the power supply component is installed in the second installation cavity 12.

[0059] The control assembly includes an IGBT module, high-voltage capacitors, a microprocessor, a driver board, a control board, a PCT-controlled MOS tube, a compressor controller, and a battery management system. Each component in the control assembly is installed in the first mounting position. For example, the IGBT module is installed above the first cooling section 21, and the high-voltage capacitor is installed above the second cooling section 22. The power supply assembly includes an on-board charger, an inverter, and a current converter. Each component in the power supply assembly is installed in three mounting areas separated by the cooling wall 221. By introducing coolant into a single cooling line 2, the coolant can pass through the second cooling section 22, the first cooling section 21, and the third cooling section 23 in sequence, achieving the effect of simultaneously and evenly cooling the control assembly and the power supply assembly. This allows the power supply assembly to be rationally and safely integrated into the electric drive controller, further improving the compactness and integration of the electric drive controller.

[0060] An embodiment of the present utility model provides a vehicle, comprising a vehicle body and an electric drive controller assembly provided by any of the aforementioned embodiments. The integrated design improves the compactness and integration of the system; at the same time, it also facilitates subsequent maintenance and repair work; in addition, it also reduces the failure rate caused by poor connection or excessively long lines. The assembly is realized by using power components and control components integrated into the electric drive controller, which ensures system compatibility and is conducive to lightweighting and reducing the size of the entire vehicle. This design improves the integrity and consistency of the vehicle system by adopting a highly integrated electric drive controller assembly, and by improving the cooling pipe 2, the heat dissipation performance of the internal assembly of the electric drive controller after the integration of the power component is also guaranteed.

[0061] As needed, the above technical solutions can be combined to achieve the best technical effect.

[0062] The above are only the principles and preferred embodiments of the present invention. It should be noted that, for those skilled in the art, on the basis of the principles of the present invention, several other modifications can be made, which should also be considered as the scope of protection of the present invention.

Claims

1. An electric drive controller housing, characterized in that: The invention comprises a housing body (1), wherein the housing body (1) comprises a first installation cavity (11) for installing a control component, a second installation cavity (12) for installing a power supply component, and a cooling pipeline (2); The first installation cavity (11) is arranged on the upper surface of the shell body (1), the second installation cavity (12) is arranged on the lower surface of the shell body (1), and the cooling pipeline (2) is partially located in the first installation cavity (11) and the second installation cavity (12).

2. The electric drive controller housing according to claim 1, characterized in that: The portion of the cooling pipeline (2) located in the first installation cavity (11) forms a first cooling portion (21), and the portion of the cooling pipeline (2) located in the second installation cavity (12) forms a second cooling portion (22), and the first cooling portion (21) is connected to the second cooling portion (22).

3. The electric drive controller housing according to claim 2, characterized in that: The first cooling portion (21) comprises a cooling groove (211) with an upward notch, and a cooling liquid inlet and a cooling liquid outlet are respectively provided at two ends of the cooling groove (211).

4. The electric drive controller housing according to claim 3, characterized in that: The cooling groove (211) is used for installing an IGBT module, and the notch of the cooling groove (211) is sealed by installing the IGBT module and a sealing ring.

5. The electric drive controller housing according to claim 2, characterized in that: The second cooling portion (22) comprises a cooling wall (221) protruding downward, the interior of the cooling wall (221) being hollowed out and in communication with the cooling pipeline (2).

6. The electric drive controller housing according to claim 5, characterized in that: The cooling wall (221) is in a U-shaped structure as a whole, so as to divide the second installation cavity (12) into three installation areas.

7. The electric drive controller housing according to claim 2, characterized in that: The water inlet (24) of the cooling pipeline (2) is opened on the side of the shell body (1) and is connected to the second cooling part (22), and the water outlet (25) of the cooling pipeline (2) is opened on the lower surface of the shell body (1) and is connected to the first cooling part (21).

8. The electric drive controller housing according to claim 7, characterized in that: The cooling pipeline (2) further comprises a third cooling portion (23) for cooling the MOS tube controlled by the PCT, and the third cooling portion (23) is located between the water outlet (25) and the first cooling portion (21).

9. An electric drive controller assembly, comprising an electric drive controller housing, a control component, and a power supply component according to any one of claims 1 to 8, wherein the control component is mounted on the first mounting cavity (11), and the power supply component is mounted on the second mounting cavity (12).

10. A vehicle, characterized in that: It comprises a vehicle body and the electric drive controller assembly as claimed in claim 9.

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