Controller cooling assembly, range extender and vehicle

Abstract

The utility model provides a controller cooling assembly, a range extender and a vehicle, the controller cooling assembly comprises a controller shell, a cavity is formed in the controller shell, and a capacitor is arranged in the cavity; a water cooling device is further arranged on one side, deviating from the cavity, of the controller shell, and at least part of the capacitor abuts against the water cooling device. According to the application, the water cooling device is arranged on the controller shell, and the capacitor is abutted against the water cooling device; when the controller operates, heat of the capacitor is conducted to the water cooling device in a contact heat transfer mode, and water flow flowing in the water cooling device can take away the heat rapidly, so that active heat dissipation of the capacitor is achieved, the temperature of the capacitor in the controller is reduced, and normal operation of the controller is guaranteed.

Description

Technical Field

[0001] The present application relates to vehicle manufacturing technology, and in particular to a controller cooling assembly, a range extender, and a vehicle. Background Art

[0002] The range extender is a key component in electric vehicles. It integrates an engine and generator. When the vehicle's battery is low, the range extender activates and burns fuel (such as gasoline) to generate electricity, charging the vehicle's battery and extending the vehicle's range. Within the range extender, a controller controls the extender's output power and adjusts its operating frequency, ensuring proper operation and system stability.

[0003] In the related technical solutions, the controller includes components such as capacitors and power modules. During operation, current is transferred from the capacitor to the power module. This process generates a large amount of heat. After long-term use, the capacitor temperature may be too high, causing the capacitor to swell, break down, explode, and other risks, affecting the normal operation of the controller. Utility Model Content

[0004] In order to overcome the above-mentioned defects in the related art, the purpose of this application is to provide a controller cooling assembly, a range extender and a vehicle. This application is conducive to reducing the temperature of the capacitor in the controller and ensuring the normal operation of the controller.

[0005] On the one hand, the present application provides a controller cooling assembly, including a controller housing, a cavity formed in the controller housing, and a capacitor provided in the cavity; a water cooling device is also provided on the side of the controller housing facing away from the cavity, and at least part of the capacitor is in contact with the water cooling device.

[0006] In one possible implementation, the water cooling device includes a water cooling channel and a water cooling end cover formed on the controller housing, and the water cooling end cover is arranged on the water cooling channel; the controller housing is also provided with a water inlet and a water outlet connected to the water cooling channel.

[0007] In a possible implementation, along the first direction, the water inlet and the water outlet are both arranged close to the first end of the water-cooling channel; along the second direction, the water inlet and the water outlet are arranged at intervals;

[0008] The water-cooling channel is provided with a dividing rib arranged along the first direction, the dividing rib dividing the water-cooling channel into a first sub-channel and a second sub-channel that are interconnected; the first sub-channel is connected to the water inlet, and the second sub-channel is connected to the water outlet;

[0009] The first direction and the second direction are perpendicular to each other.

[0010] In one possible implementation, along the first direction, the dividing rib extends from the first end of the water-cooling channel to the second end of the water-cooling channel; the portion of the dividing rib away from the first end of the water-cooling channel is bent toward the first sub-channel, and the ratio of the gap between the dividing rib and the second end of the water-cooling channel to the size of the water-cooling channel along the first direction is 12.4%-18.6%.

[0011] In a possible implementation, an oil channel is further provided on a side of the controller housing facing the cavity, and a protrusion is provided in an area of ​​the water-cooled end cover corresponding to the oil channel.

[0012] In a possible implementation, the capacitor is in contact with the water cooling device via a heat transfer device.

[0013] In a possible implementation, the heat transfer device includes a metal plate and a thermally conductive adhesive layer, the metal plate is disposed on the capacitor, and the thermally conductive adhesive layer is disposed on the controller housing.

[0014] In a possible implementation, a first groove and a second groove are further provided on one side of the controller housing facing the cavity, the first groove and the second groove are respectively located on both sides of the oil channel along the first direction, and the thermal conductive adhesive layer is filled in the first groove and the second groove.

[0015] On the other hand, the present application provides a range extender, comprising a controller and a motor connected thereto, wherein the controller comprises a controller cooling assembly as described above, wherein the water cooling device is located on a side of the controller housing facing the motor.

[0016] On the other hand, the present application provides a vehicle including the range extender as described above.

[0017] The present application provides a controller cooling assembly, a range extender, and a vehicle. The controller cooling assembly includes a controller housing, a cavity formed in the controller housing, and a capacitor disposed in the cavity. A water cooling device is also disposed on the side of the controller housing facing away from the cavity, and at least part of the capacitor is in contact with the water cooling device. The present application provides a water cooling device on the controller housing and abuts the capacitor against the water cooling device. When the controller is running, the heat of the capacitor is transferred to the water cooling device by contact heat transfer. The water flowing in the water cooling device can quickly carry away the heat, thereby achieving active heat dissipation of the capacitor, which is beneficial to reducing the temperature of the capacitor in the controller and ensuring the normal operation of the controller. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to more clearly illustrate the technical solutions in the embodiments of the present application or related technologies, the following is a brief introduction to the drawings required for use in the embodiments or related technical descriptions. Obviously, the drawings described below are some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0019] Figure 1 It is a simplified structural diagram of a controller in the related art;

[0020] Figure 2 It is a simplified structural diagram of a capacitor in the related art;

[0021] Figure 3 A schematic diagram of the partial structure of a range extender provided in one embodiment of the present application;

[0022] Figure 4 A simplified structural diagram of a controller housing provided in an embodiment of the present application from a first viewing angle;

[0023] Figure 5 A simplified structural diagram of a controller housing provided in an embodiment of the present application at a second viewing angle;

[0024] Figure 6 A simplified structural diagram of a water-cooled end cover provided in one embodiment of the present application;

[0025] Figure 7 A simplified structural diagram of a capacitor provided in one embodiment of the present application.

[0026] Reference numerals:

[0027] 10-controller; 11-filter; 12-power module;

[0028] 20-motor;

[0029] 100 - controller housing; 110 - thermal conductive adhesive layer; 120 - first groove; 130 - second groove;

[0030] 200-capacitor; 201-metal plate; 210-capacitor housing; 220-capacitor core; 230-busbar;

[0031] 300 - water cooling device; 310 - water cooling channel; 311 - first sub-channel; 312 - second sub-channel; 320 - water cooling end cover; 321 - raised portion; 3211 - first sub-raised portion; 3212 - second sub-raised portion; 330 - water inlet; 340 - water outlet; 350 - separation rib;

[0032] 400-Oil channel;

[0033] X-first direction; Y-second direction; Z-third direction. DETAILED DESCRIPTION

[0034] In order to make the purpose, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be clearly and completely described below in combination with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments.

[0035] Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application. In the absence of conflict, the following embodiments and features in the embodiments can be combined with each other.

[0036] As described in the background art, in the solutions of the related art, the temperature of the capacitor of the range extender controller may be too high after long-term use, causing the capacitor to have risks such as swelling, breakdown, and explosion, affecting the normal operation of the controller.

[0037] Specifically, such as Figure 1 As shown, the controller 10 in the related art mainly includes components such as a filter 11, a capacitor 200, and a power module 12, wherein the capacitor 200 is electrically connected to the power module 12 (for example, the capacitor 200 is electrically connected to the power module 12 through components such as a bus bar). Figure 1 As shown by the middle arrow, when the controller 10 is running, the current passes through the filter 11 and the capacitor 200 in sequence and then reaches the power module 12. When the power module 12 is running, a higher temperature (temperature greater than 90°C) will be generated. The heat is transferred to the capacitor 200 through the bus in a contact heat transfer manner, causing the temperature of the capacitor 200 to rise.

[0038] In addition, if Figure 2 As shown, the capacitor 200 includes a capacitor housing 210, a plurality of capacitor cores 220 and a busbar 230. The plurality of capacitor cores 220 are all arranged in the capacitor housing 210. The busbar 230 is arranged through the capacitor housing 210 and abuts against the plurality of capacitor cores 220. Figure 2 As shown by the middle arrow, when the controller 10 is running, current enters from one terminal of the busbar 230 and flows out from the other terminal of the busbar 230. When the current passes through, the busbar 230 will heat up, thereby causing the temperature of the capacitor core 220 to rise.

[0039] From the above description, it can be seen that in the solution of the related technology, when the controller 10 is running, the heat transfer of the power module 12 and the heat generated by the capacitor 200 itself during operation will cause the temperature of the capacitor 200 to rise, causing the capacitor 200 to have risks such as swelling, breakdown, and explosion, thereby affecting the normal operation of the controller 10.

[0040] In view of this, the embodiments of the present application aim to provide a controller cooling assembly, a range extender and a vehicle, by arranging a water cooling device on the controller housing and abutting the capacitor against the water cooling device; when the controller is running, the heat of the capacitor is transferred to the water cooling device through contact heat transfer, and the water flowing in the water cooling device can quickly take away the heat, thereby realizing active heat dissipation of the capacitor, which is beneficial to reducing the temperature of the capacitor in the controller and ensuring the normal operation of the controller.

[0041] The following describes the embodiments of the present application in detail with reference to the accompanying drawings so that those skilled in the art can understand the contents of the present application in more detail. It should be noted that in the description of this embodiment, the first direction X, the second direction Y, and the third direction Z are three different directions in a three-dimensional space. For example, the first direction X, the second direction Y, and the third direction Z can be perpendicular to each other.

[0042] Please refer to Figure 3-Figure 7 , this embodiment provides a controller cooling assembly, including a controller housing 100, a cavity formed in the controller housing 100, and a capacitor 200 is arranged in the cavity. A water cooling device 300 is also provided on the side of the controller housing 100 facing away from the cavity, and at least part of the capacitor 200 abuts against the water cooling device 300. It can be understood that the water cooling device 300 is formed on the controller housing 100, and the capacitor 200 arranged in the cavity directly abuts against the water cooling device 300; illustratively, the capacitor 200 can abut against the water cooling device 300 by, for example, bonding or the like. Preferably, in a plane perpendicular to the third direction Z, the projection of the capacitor 200 is located within the projection range of the water cooling device 300, thereby ensuring that the capacitor 200 can abut against the water cooling device 300 at all locations, so as to improve the heat dissipation efficiency of the capacitor 200.

[0043] In this embodiment, a water cooling device 300 is provided on the controller housing 100, and the capacitor 200 is abutted against the water cooling device 300; when the controller is running, the heat of the capacitor 200 is transferred along the water cooling device 300 by contact heat transfer. Figure 3 The direction of the arrow shown is transmitted to the water cooling device 300. The water flowing in the water cooling device 300 can quickly take away the heat, thereby realizing active heat dissipation of the capacitor 200, which is beneficial to reducing the temperature of the capacitor 200 in the controller and ensuring the normal operation of the controller.

[0044] Please continue to refer to Figure 3-Figure 6The water cooling device 300 of this embodiment includes a water cooling channel 310 and a water cooling end cover 320 formed on the controller housing 100. For example, the water cooling channel 310 can be formed by a groove on the controller housing 100, and the water cooling end cover 320 is disposed on the water cooling channel 310. The water cooling end cover 320 and the water cooling channel 310 can be sealed by methods such as stir friction welding, thereby ensuring the sealing of the water cooling device 300. The controller housing 100 is also provided with a water inlet 330 and a water outlet 340 that communicate with the water cooling channel 310. When the controller is in operation, water flows into the water cooling channel 310 from the water inlet 330 and flows out from the water outlet 340. The flowing water can quickly remove the heat transferred from the capacitor 200, thereby reducing the temperature of the capacitor 200.

[0045] like Figure 5 As shown, along the first direction X, the water inlet 330 and the water outlet 340 are both located near the first end of the water-cooling channel 310. Along the second direction Y, the water inlet 330 and the water outlet 340 are spaced apart. For example, the second direction Y can be the direction of gravity, and the water inlet 330 is located above the water outlet 340, so that water can flow from the water inlet 330 to the water outlet 340 under the combined action of gravity and external force.

[0046] The water-cooling channel 310 is further provided with a dividing rib 350 arranged along the first direction X. The dividing rib 350 divides the water-cooling channel 310 into a first sub-channel 311 and a second sub-channel 312 that are interconnected. The first sub-channel 311 is connected to the water inlet 330, and the second sub-channel 312 is connected to the water outlet 340. The setting of the dividing rib 350 can change the flow direction of the water in the water-cooling channel 310, so that the water flows along the first sub-channel 311 and the second sub-channel 312. Figure 5 The water flows in the direction of the arrow shown, completely filling the water-cooling channel 310 , ensuring that the flowing water can completely cover the abutting surface of the capacitor 200 , thereby enabling the capacitor 200 to have a better heat dissipation effect.

[0047] Furthermore, along the first direction X, the dividing rib 350 extends from the first end of the water-cooling channel 310 to the second end of the water-cooling channel 310. The portion of the dividing rib 350 away from the first end of the water-cooling channel 310 bends toward the first sub-channel 311, and the ratio of the gap D between the dividing rib 350 and the second end of the water-cooling channel 310 to the dimension of the water-cooling channel 310 along the first direction X is 12.4%-18.6%. This structure, on the one hand, prevents turbulence at the junction of the first sub-channel 311 and the second sub-channel 312, ensuring normal water flow; on the other hand, it reduces the pressure drop of the water flow, ensuring the water flow rate within the water-cooling channel 310, thereby improving the heat dissipation efficiency of the capacitor 200.

[0048] Please refer to Figure 4 and Figure 6 ,in Figure 4 The arrow in the middle shows the direction of water flow in the water cooling channel 310. The controller housing 100 of this embodiment is also provided with an oil channel 400 on the side facing the cavity. Figure 4 It can be seen that the oil channel 400 is generally arranged along the second direction Y, and a portion of the oil channel 400 and the water-cooling channel 310 have an overlapping projection area. In this area, the oil channel 400 occupies a portion of the space of the water-cooling channel 310, reducing the volume of the water-cooling channel 310. Figure 6 As shown, in this embodiment, a protrusion 321 is further provided in the area corresponding to the water-cooling end cover 320 and the oil channel 400. The protrusion 321 includes a first sub-protrusion 3211 corresponding to the first sub-channel 311 and a second sub-protrusion 3212 corresponding to the second sub-channel 312. The provision of the protrusion 321 increases the volume of the water-cooling channel 310, which is beneficial to reducing the impact of the oil channel 400 on the volume of the water-cooling channel 310, and ensures that the water-cooling channel 310 in the area overlapping with the oil channel 400 has sufficient flow area.

[0049] Please continue to refer to Figure 3 and Figure 7 In this embodiment, the capacitor 200 is further connected to the water cooling device 300 through a heat transfer device. The heat transfer device can further improve the heat transfer efficiency, thereby improving the heat dissipation efficiency of the capacitor 200.

[0050] Optionally, the heat transfer device of this embodiment includes a metal plate 201 and a thermally conductive adhesive layer 110. The metal plate 201 can be made of a material with high thermal conductivity, such as aluminum or copper. The metal plate 201 is disposed on the capacitor 200, and the thermally conductive adhesive layer 110 is disposed on the controller housing 100. The metal plate 201 is bonded to the water cooling device 300 on the controller housing 100 via the thermally conductive adhesive layer 110.

[0051] In this embodiment, the capacitor 200 includes a capacitor housing 210, a plurality of capacitor cores 220, and a busbar 230. The plurality of capacitor cores 220 are all disposed within the capacitor housing 210, and the busbar 230 is disposed through the capacitor housing 210 and abuts against the plurality of capacitor cores 220. An opening is formed at one end of the capacitor housing 210, and the plurality of capacitor cores 220 are all placed into the capacitor housing 210 through the opening and abut against the busbar 230. After the capacitor cores 220 are placed, epoxy resin can be filled into the capacitor housing 210 through the opening, and the epoxy resin fills the remaining space within the capacitor housing 210. A metal plate 201 is provided to cover the opening and is fixed with epoxy resin. When the capacitor 200 is placed in the cavity of the controller housing 100, the side provided with the metal plate 201 is bonded to the thermally conductive adhesive layer 110 on the controller housing 100, thereby increasing the heat transfer rate of the capacitor 200.

[0052] Please continue to refer to Figure 4In this embodiment, a first groove 120 and a second groove 130 are further provided on the side of the controller housing 100 facing the cavity. The first groove 120 and the second groove 130 are respectively located on both sides of the oil passage 400 along the first direction X. The thermal conductive adhesive layer 110 is filled in the first groove 120 and the second groove 130. In this embodiment, by arranging the thermal conductive adhesive layer 110 on both sides of the oil passage 400 along the first direction X, the thermal conductive adhesive layer 110 avoids the oil passage 400, thereby preventing the heat from the oil passage 400 from being transferred to the capacitor 200. For example, the first groove 120 and the second groove 130 of this embodiment can be formed on the controller housing 100 by machining. The depth of the first groove 120 and the second groove 130 can be set as needed, for example, it can be 0.05-0.2 mm, so as to facilitate the operator to inject the thermal conductive adhesive.

[0053] Please continue to refer to Figure 3 This embodiment also provides a range extender, including a controller 10 and a motor 20 connected to each other, the controller 10 including the above-mentioned controller 10 cooling assembly, wherein the water cooling device 300 is located on the side of the controller 10 housing 100 facing the motor 20.

[0054] It can be understood that when the range extender of this embodiment is running, the heat of the capacitor 200 in the controller 10 can be transferred to the water cooling device 300 through contact heat transfer. The water flowing in the water cooling device 300 can quickly take away the heat, thereby achieving active heat dissipation of the capacitor 200, which is beneficial to reducing the temperature of the capacitor 200 in the controller 10 and ensuring the normal operation of the controller 10.

[0055] This embodiment also provides a vehicle, including the above-mentioned range extender.

[0056] Since the vehicle of this embodiment adopts the above-mentioned range extender, the heat of the internal capacitor when the range extender is running can be reduced, which is beneficial to improving the stability of vehicle operation.

[0057] In the description of the present application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application 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, and therefore should not be understood as a limitation on the present application.

[0058] In this application, unless otherwise expressly specified or limited, terms such as "mounted," "connected," "connect," and "fixed" should be interpreted broadly. For example, they may refer to fixed connection, detachable connection, or integration; they may refer to direct connection or indirect connection through an intermediate medium; they may refer to internal communication between two components or interaction between two components. Those skilled in the art will understand the specific meanings of these terms in this application based on the specific circumstances.

[0059] It should be noted that in the description of this application, the terms "first" and "second" are used solely to facilitate the description of different components and should not be understood to indicate or imply a sequential relationship, relative importance, or implicitly specify the number of technical features indicated. Therefore, features specified as "first" or "second" may explicitly or implicitly include at least one of such features.

[0060] The various embodiments or implementation methods in this application are described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the various embodiments can be referenced to each other.

[0061] In the description of this application, reference to the terms "one embodiment," "some embodiments," "illustrative embodiments," "examples," "specific examples," or "some examples" means that the specific features, structures, materials, or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of this application. In this application, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in any appropriate manner in any one or more embodiments or examples.

[0062] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them. Although the present application 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 or all of the technical features therein. These modifications or replacements do not deviate the essence of the corresponding technical solutions from the scope of the technical solutions of the embodiments of the present application.

Claims

1. A controller cooling assembly, characterized in that: It comprises a controller shell, a cavity is formed in the controller shell, and a capacitor is arranged in the cavity; a water cooling device is also provided on the side of the controller shell away from the cavity, and at least part of the capacitor is in contact with the water cooling device.

2. The controller cooling assembly according to claim 1, characterized in that: The water cooling device includes a water cooling channel and a water cooling end cover formed on the controller housing, and the water cooling end cover is arranged on the water cooling channel; the controller housing is also provided with a water inlet and a water outlet connected to the water cooling channel.

3. The controller cooling assembly according to claim 2, characterized in that: Along the first direction, the water inlet and the water outlet are both arranged close to the first end of the water-cooling channel; along the second direction, the water inlet and the water outlet are arranged at intervals; The water-cooling channel is provided with a dividing rib arranged along the first direction, the dividing rib dividing the water-cooling channel into a first sub-channel and a second sub-channel that are interconnected; the first sub-channel is connected to the water inlet, and the second sub-channel is connected to the water outlet; The first direction and the second direction are perpendicular to each other.

4. The controller cooling assembly according to claim 3, characterized in that: Along the first direction, the dividing rib extends from the first end of the water-cooling channel to the second end of the water-cooling channel; the portion of the dividing rib away from the first end of the water-cooling channel is bent toward the first sub-channel, and the ratio of the gap between the dividing rib and the second end of the water-cooling channel to the size of the water-cooling channel along the first direction is 12.4%-18.6%.

5. The controller cooling assembly according to claim 3, characterized in that: An oil passage is further provided on a side of the controller housing facing the cavity, and a protrusion is provided in an area of ​​the water-cooled end cover corresponding to the oil passage.

6. The controller cooling assembly according to claim 5, characterized in that: The capacitor is in contact with the water cooling device via a heat transfer device.

7. The controller cooling assembly according to claim 6, characterized in that: The heat transfer device includes a metal plate and a heat-conducting adhesive layer. The metal plate is arranged on the capacitor, and the heat-conducting adhesive layer is arranged on the controller housing.

8. The controller cooling assembly according to claim 7, characterized in that: A first groove and a second groove are further provided on one side of the controller housing facing the cavity. The first groove and the second groove are respectively located on both sides of the oil channel along the first direction. The thermal conductive adhesive layer is filled in the first groove and the second groove.

9. A range extender, characterized in that: It comprises a controller and a motor connected to each other, wherein the controller comprises a controller cooling assembly as described in any one of claims 1 to 8, wherein the water cooling device is located on a side of the controller housing facing the motor.

10. A vehicle, characterized in that: Comprising the range extender as claimed in claim 9.

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