Non-standard motor controller for vehicle

Abstract

The utility model relates to the related technical field of power electronics, in particular to a non-standard motor controller for a vehicle, which comprises a power module mechanism, a fixing screw (2) is arranged on the surface of one side of the power module mechanism, and a capacitor module mechanism is arranged on the surface of one side of the fixing screw. According to the design scheme, before the power module and the DC-Link are combined, the power module and the DC-Link can be independently detected, and after the power module and the DC-Link are ensured to be qualified, the power module and the DC-Link are combined, so that the requirement of independently detecting the power module and the DC-Link capacitor is met, and meanwhile, after the power module and the DC-Link capacitor are combined, the requirements of extremely small ESL (equivalent series inductor) performance and compact product size of a product are met; and the rejection rate / rejection cost of the product is correspondingly reduced.

Description

Technical Field

[0001] The utility model relates to the technical field related to power electronics, and in particular to a non-standard motor controller for a vehicle. Background Art

[0002] In the modern automotive industry, power electronics technology plays a vital role. In traditional fuel vehicles, power electronics technology is used in power supply and lighting systems for on-board electronic equipment. With the development trend of new energy vehicles and automobile intelligence and electrification, the status of power electronics technology in automobiles is becoming more and more critical. In new energy vehicles, the DC power output by the battery needs to be converted into AC power suitable for motor operation through the motor controller. In this process, it is not easy to achieve efficient, stable and precise power conversion. On the one hand, different types of motors (such as permanent magnet synchronous motors, asynchronous motors, etc.) have different requirements for driving signals, and the motor controller needs to be able to flexibly adjust the output voltage, frequency, phase and other parameters. On the other hand, the automobile operating environment is complex and changeable, from extreme cold to high temperature, from flat roads to rugged mountain roads. The motor controller must ensure stable and reliable operation under various working conditions. Therefore, a non-standard motor controller for automobiles is particularly needed.

[0003] However, existing motor controllers often use an integrated design that integrates the power module and DC-Link capacitor to reduce product ESL and size. That is, the power module and DC-Link capacitor are integrated and cannot be separated. This integrated design makes it difficult to detect the power module and DC-Link capacitor separately, and increases the product scrap rate and scrap cost. Utility Model Content

[0004] The present invention aims to provide a non-standard motor controller for a vehicle, so as to solve the problem that the existing motor controllers proposed in the above background technology often adopt an integrated design of power module and DC-Link capacitor to reduce product ESL and size, that is, the power module and DC-Link capacitor are integrated together and cannot be separated. This integrated design makes it difficult to detect the power module and DC-Link capacitor separately, and increases the product scrap rate / scrap cost.

[0005] To achieve the above-mentioned object, the present invention provides the following technical solution: a non-standard motor controller for a vehicle, comprising a power module mechanism, a fixing screw being provided on one side surface of the power module mechanism, and a capacitor module mechanism being provided on one side surface of the fixing screw;

[0006] The power module mechanism includes a module frame, a baffle, a module, a first positive pole connecting copper column, a negative pole connecting copper column, a second positive pole connecting copper column and epoxy resin. One side surface of the fixing screw is fixedly connected to the module frame, the inner side surface of the module frame is fixedly connected to the baffle, the upper surface of the module frame is fixedly connected to the module, the upper surface of the module is fixedly connected to the first positive pole connecting copper column, the upper surface of the module is fixedly connected to the negative pole connecting copper column, the upper surface of the module is fixedly connected to the second positive pole connecting copper column, and the upper surface of the module frame is fixedly connected to the epoxy resin.

[0007] Preferably, a baffle is designed in the module frame to isolate the first positive electrode connecting copper column, the negative electrode connecting copper column and the second positive electrode connecting copper column by electrical gap, and the connecting copper columns are welded by a welding process and fixed to the module.

[0008] Preferably, the capacitor module mechanism includes a capacitor frame, a capacitor retaining wall, a capacitor epoxy resin, a T+ capacitor copper busbar, insulating paper, a T-insulating copper busbar and a capacitor core, one side surface of the fixing screw is fixedly connected to the capacitor frame, the inner side surface of the capacitor frame is fixedly connected to the capacitor retaining wall, one side surface of the capacitor frame is fixedly connected to the capacitor retaining wall, the inner side surface of the capacitor frame is fixedly connected to the capacitor epoxy resin, one side surface of the capacitor frame is fixedly connected to the T+ capacitor copper busbar, one side surface of the T+ capacitor copper busbar is adhered to insulating paper, one side surface of the insulating paper is adhered to the T-insulating copper busbar, and one side surface of the capacitor frame is fixedly connected to the capacitor core.

[0009] Preferably, epoxy resin is encapsulated in the rectangular cavity surrounded by the module frame and the baffle, and the epoxy resin encapsulation height is slightly lower than the connecting copper column, that is, the surface of the connecting copper column is exposed, and the connecting copper column is connected to the capacitor copper busbar by laser welding process.

[0010] Preferably, the fixing screw locks and fixes the power module mechanism and the capacitor module mechanism at the capacitor nut, and the capacitor frame wraps the T+ capacitor copper busbar, the insulating paper and the T-insulating copper busbar.

[0011] Preferably, the capacitor retaining wall electrically isolates the T+ capacitor copper busbar from the T- capacitor copper busbar, and the insulating paper electrically isolates the T+ capacitor copper busbar from the T- insulating copper busbar, and the three are pressed together to form a laminated copper busbar capacitor copper busbar assembly.

[0012] Preferably, the T+ capacitor copper busbar and the T-insulating copper busbar are laser-welded to the first positive connection copper column, the negative connection copper column and the second positive connection copper column respectively, and the power module mechanism and the capacitor module mechanism are separated before the fixing screws and the laser-welded T+ capacitor copper busbar and the T-capacitor copper busbar are screwed.

[0013] Compared with the existing technology, the beneficial effect of the present invention is that before the power module and DC-Link are combined, the two can be tested separately to ensure that both are qualified before they are combined. This not only meets the requirements of separate testing of the power module and DC-Link capacitors, but also meets the product's extremely low ESL (equivalent series inductance) performance and compact product size requirements after the two are combined, and the product scrap rate / scrap cost is also reduced accordingly. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 This is a side view of the structure of the utility model;

[0015] Figure 2 This is a schematic diagram of the position relationship of the fixing screws in this utility model;

[0016] Figure 3 This is a side view of the structure of the capacitor core of this practical application;

[0017] Figure 4 This is a schematic diagram of the structure in which the first positive electrode connecting copper pillar, the negative electrode connecting copper pillar and the second positive electrode connecting copper pillar cooperate with each other;

[0018] Figure 5 This is a side view of the structure of the baffle of this utility model;

[0019] Figure 6 This is a schematic diagram of the appearance structure of the practical epoxy resin;

[0020] Figure 7 This is a schematic diagram of the structure of the practical capacitor frame, capacitor retaining wall and capacitor epoxy resin cooperating with each other;

[0021] Figure 8 This is a schematic diagram of the structure of the T+ capacitor copper bus, insulation paper and T-insulation copper bus in cooperation with each other;

[0022] In the figure: 1. Power module structure; 101. Module frame; 102. Baffle; 103. Module; 104. First positive pole connecting copper pillar; 105. Negative pole connecting copper pillar; 106. Second positive pole connecting copper pillar; 107. Epoxy resin; 2. Fixing screws; 3. Capacitor module structure; 301. Capacitor frame; 302. Capacitor retaining wall; 303. Capacitor epoxy resin; 304. T+ capacitor copper busbar; 305. Insulation paper; 306. T-insulation copper busbar; 307. Capacitor core. DETAILED DESCRIPTION

[0023] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0024] See also Figure 1-8 The utility model provides a technical solution: a non-standard motor controller for a vehicle, comprising a power module mechanism 1, a fixing screw 2 is provided on one side surface of the power module mechanism 1, and a capacitor module mechanism 3 is provided on one side surface of the fixing screw 2;

[0025] The power module mechanism 1 includes a module frame 101, a baffle 102, a module 103, a first positive connection copper column 104, a negative connection copper column 105, a second positive connection copper column 106 and an epoxy resin 107. The side surface of the fixing screw 2 is fixedly connected to the module frame 101, the inner side surface of the module frame 101 is fixedly connected to the baffle 102, the upper surface of the module frame 101 is fixedly connected to the module 103, the upper surface of the module 103 is fixedly connected to the first positive connection copper column 104, the upper surface of the module 103 is fixedly connected to the negative connection copper column 105, the upper surface of the module 103 is fixedly connected to the second positive connection copper column 106, and the upper surface of the module frame 101 is fixedly connected to the epoxy resin 107. The arrangement of the first positive pole connecting copper pillar 105, the second positive pole connecting copper pillar 106 and the epoxy resin 107. When in use, the baffle 102 on the inner side of the module frame 101 can play the role of electrical gap isolation for the connecting copper pillars. For example, during the operation of the power module, the connecting copper pillars of different polarities may interfere with each other due to the action of the electric field. The baffle 102 can effectively block this interference, ensure the stability of the electrical performance between each connecting copper pillar, thereby improving the working reliability of the entire power module, and the epoxy resin 107 on the upper surface of the module frame 101 can play the role of encapsulation and protection for the module 103 and components such as the connecting copper pillars. Epoxy resin has good insulation properties and chemical stability, which can prevent impurities such as dust and moisture from entering the module, avoid corrosion or short circuit and other damage to the internal circuit, and extend the service life of the power module.

[0026] Furthermore, a baffle 102 is designed in the module frame 101 to electrically isolate the first positive connecting copper column 104, the negative connecting copper column 105 and the second positive connecting copper column 106. The connecting copper columns are welded through a welding process and fixed on the module 103. Through the setting of the baffle 102, when in use, the baffle 102 electrically isolates the connecting copper columns, which can effectively reduce the electromagnetic coupling between the connecting copper columns of different polarities and reduce electromagnetic interference. When the power module is working, the current passes through the connecting copper columns. If there is no effective isolation, the magnetic fields generated by the currents of different polarities may affect each other, resulting in signal distortion, circuit performance degradation and other problems. Through this isolation measure, the electromagnetic compatibility of the circuit can be improved, so that the power module can work stably in a complex electromagnetic environment.

[0027] Furthermore, the capacitor module mechanism 3 includes a capacitor frame 301, a capacitor retaining wall 302, a capacitor epoxy resin 303, a T+ capacitor copper bus 304, an insulating paper 305, a T-insulating copper bus 306 and a capacitor core 307. One side surface of the fixing screw 2 is fixedly connected to the capacitor frame 301, the inner side surface of the capacitor frame 301 is fixedly connected to the capacitor retaining wall 302, one side surface of the capacitor frame 301 is fixedly connected to the capacitor retaining wall 302, the inner side surface of the capacitor frame 301 is fixedly connected to the capacitor epoxy resin 303, one side surface of the capacitor frame 301 is fixedly connected to the T+ capacitor copper bus 304, one side surface of the T+ capacitor copper bus 304 is adhered to the insulating paper 305, one side surface of the insulating paper 305 is adhered to the T-insulating copper bus 306, one side surface of the capacitor frame 301 is fixedly connected to the capacitor core 307, and through the capacitor frame 301, the capacitor retaining wall 302, the capacitor epoxy resin 303 , T+ capacitor copper bus 304, insulating paper 305, T-insulating copper bus 306 and capacitor core 307 are arranged. When in use, the capacitor retaining wall 302 electrically isolates the T+ capacitor copper bus 304 and the T-insulating copper bus 306 in the capacitor frame 301, which can effectively prevent short circuits between capacitor copper buses of different polarities and ensure the normal operation of the capacitor module. During the charging and discharging process of the capacitor, if there is no good isolation between the copper buses of different polarities, it may cause the charge to flow directly between the copper buses instead of through the capacitor core 307, thereby affecting the performance of the capacitor and the stability of the entire circuit. The insulating paper 305 further enhances the insulation effect between the T+ capacitor copper bus 304 and the T-insulating copper bus 306. It can make up for the tiny gap that may exist in the capacitor retaining wall 302, provide additional insulation protection, and ensure that the electrical performance of the capacitor module is stable and reliable under high voltage and high current working environments.

[0028] Furthermore, epoxy resin 107 is encapsulated in the rectangular cavity surrounded by the module frame 101 and the baffle 102. The encapsulation height of the epoxy resin 107 is slightly lower than the connecting copper column, that is, the surface of the connecting copper column is exposed. The connecting copper column is connected to the capacitor copper bus through a laser welding process. Through the setting of the epoxy resin 107, when in use, the encapsulation height of the epoxy resin 107 is slightly lower than the design of the connecting copper column, so that the connecting copper column is exposed for welding, which helps to reduce the size of the assembled product. Compared with the case where the epoxy resin completely covers the connecting copper column, this design does not require additional processing of the epoxy resin to expose the connection part for welding, reduces space occupancy, makes the product structure more compact, and conforms to the development trend of miniaturization of motor controllers.

[0029] Furthermore, the fixing screw 2 locks and fixes the power module mechanism 1 and the capacitor module mechanism 3 at the capacitor nut, and the capacitor frame 301 wraps the T+ capacitor copper bus 304, the insulating paper 305 and the T- insulating copper bus 306. By setting the fixing screw 2 and the capacitor frame 301, when in use, the fixing screw 2 locks and fixes the power module mechanism 1 and the capacitor module mechanism 3 at the capacitor nut. This fixing method can make the two modules tightly combined to form a stable overall structure. In the actual application of the motor controller, whether it is vibration during vehicle driving or the action of other external mechanical forces, this firm fixation can prevent the power module from vibrating. Relative displacement occurs between the block and the capacitor module, thereby ensuring the mechanical stability of the entire structure and ensuring that the motor controller can work normally. The capacitor frame 301 wraps the T+ capacitor copper bus 304, the insulating paper 305 and the T- insulating copper bus 306, playing a good electrical isolation role. It can prevent the external environment from interfering with the capacitor copper bus, and also avoid short circuits between the capacitor copper buses due to accidental contact. In the circuit of the motor controller, the normal operation of the capacitor copper bus is crucial to the performance of the entire circuit. This electrical isolation and protection measure can ensure the stable electrical performance of the capacitor module, thereby improving the working efficiency and reliability of the entire motor controller.

[0030] Furthermore, the capacitor retaining wall 302 electrically isolates the T+ capacitor copper bus 304 from the T- capacitor copper bus 304, and the insulating paper 305 electrically isolates the T+ capacitor copper bus 304 from the T- insulating copper bus. The three are pressed together to form a laminated copper bus capacitor copper bus assembly. Through the setting of the capacitor retaining wall 302 and the insulating paper 305, when in use, the capacitor retaining wall 302 and the insulating paper 305 electrically isolate the T+ capacitor copper bus 304 from the T- capacitor copper bus (or T- insulating copper bus) respectively. This double isolation measure greatly enhances the electrical isolation effect. During the operation of the capacitor module, if there is not enough isolation between copper buses of different polarities, short circuit failures may occur, affecting the normal charging and discharging of the capacitor, and then affecting the stability of the entire circuit. Through this double isolation, the occurrence of short circuits can be effectively avoided, ensuring the stability of the electrical performance of the capacitor module.

[0031] Furthermore, the T+ capacitor copper bus 304 and the T-insulated copper bus 306 are respectively connected to the first positive connection copper pillar 104, the negative connection copper pillar 105 and the second positive connection copper pillar 106 by laser welding. Before the fixing screws 2 and the laser welding T+ capacitor copper bus 304 and T- capacitor copper bus 304 are screwed, the power module mechanism 1 and the capacitor module mechanism 3 are separated. By setting the + capacitor copper bus 304, the T-insulated copper bus 306, the first positive connection copper pillar 104, the negative connection copper pillar 105 and the second positive connection copper pillar 106, when in use, the T+ capacitor copper bus 304 and the T-insulated copper bus 306 are respectively connected to the first positive connection copper pillar 104, the negative connection copper pillar 105 and the second positive connection copper pillar 106 by laser welding. Laser welding has the advantages of concentrated energy, fast welding speed, and good weld quality. It can ensure the electrical connection quality of the connection parts. High-quality electrical connections can ensure efficient transmission of electrical energy between the power module and the capacitor module, reduce power loss and contact resistance, and improve the electrical performance of the entire system. The fixing screws 2 play a role in fixing the power module mechanism 1 and the capacitor module mechanism 3 during the assembly process. After the laser welding is completed, the two modules are further fixed by fixing the screws to enhance the stability of the entire structure. In the actual application of the motor controller, it may be subject to external forces such as vibration and impact. The combined effect of fixing screws and laser welding can ensure a firm connection between the power module and the capacitor module to prevent loosening or displacement, and ensure the normal operation of the system.

[0032] Working principle: In this non-standard automotive motor controller, before screwing the screws and laser welding the T+ capacitor copper busbar 305 and the T- capacitor copper busbar 307, the power module mechanism 1 and the capacitor module mechanism 3 are separated. In the separated state, the power module mechanism 1 and the capacitor module mechanism 3 can be easily and independently tested. After both are tested OK, they are assembled and connected. This can reduce the increase in equipment costs caused by the inability to separate and independently test the two components, as well as the increase in product scrap rate / scrap cost due to unqualified combination caused by failure to separately test the two components first.

[0033] Although the embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations may be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A non-standard motor controller for a vehicle, comprising a power module mechanism (1), characterized in that: A fixing screw (2) is provided on one side surface of the power module mechanism (1), and a capacitor module mechanism (3) is provided on one side surface of the fixing screw (2); The power module mechanism (1) comprises a module frame (101), a baffle (102), a module (103), a first positive pole connection copper pillar (104), a negative pole connection copper pillar (105), a second positive pole connection copper pillar (106) and an epoxy resin (107); a side surface of the fixing screw (2) is fixedly connected to the module frame (101); an inner side surface of the module frame (101) is fixedly connected to the baffle (102); an upper surface of the module frame (101) is fixedly connected to the module (103); an upper surface of the module (103) is fixedly connected to the first positive pole connection copper pillar (104); an upper surface of the module (103) is fixedly connected to the negative pole connection copper pillar (105); an upper surface of the module (103) is fixedly connected to the second positive pole connection copper pillar (106); and an upper surface of the module frame (101) is fixedly connected to the epoxy resin (107).

2. The non-standard motor controller for a vehicle according to claim 1, characterized in that: The module frame (101) is provided with a baffle (102) for electrically isolating the first positive electrode connecting copper column (104), the negative electrode connecting copper column (105) and the second positive electrode connecting copper column (106). The connecting copper columns are welded and fixed to the module (103) through a welding process.

3. The non-standard motor controller for a vehicle according to claim 1, characterized in that: The capacitor module mechanism (3) comprises a capacitor frame (301), a capacitor retaining wall (302), a capacitor epoxy resin (303), a T+ capacitor copper busbar (304), an insulating paper (305), a T-insulating copper busbar (306) and a capacitor core (307); one side surface of the fixing screw (2) is fixedly connected to the capacitor frame (301); the inner side surface of the capacitor frame (301) is fixedly connected to the capacitor retaining wall (302); and one side surface of the capacitor frame (301) is fixedly connected to the capacitor retaining wall (302). A capacitor retaining wall (302) is provided, the inner surface of the capacitor frame (301) is fixedly connected with capacitor epoxy resin (303), one side surface of the capacitor frame (301) is fixedly connected with a T+ capacitor copper busbar (304), one side surface of the T+ capacitor copper busbar (304) is adhered with insulating paper (305), one side surface of the insulating paper (305) is adhered with a T-insulating copper busbar (306), and one side surface of the capacitor frame (301) is fixedly connected with a capacitor core (307).

4. The non-standard motor controller for a vehicle according to claim 3, characterized in that: Epoxy resin (107) is encapsulated in a rectangular cavity surrounded by the module frame (101) and the baffle (102). The encapsulation height of the epoxy resin (107) is slightly lower than the connecting copper column, that is, the surface of the connecting copper column is exposed. The connecting copper column is connected to the capacitor copper busbar by a laser welding process.

5. The non-standard motor controller for a vehicle according to claim 3, characterized in that: The fixing screws (2) lock and fix the power module mechanism (1) and the capacitor module mechanism (3) at the capacitor nut, and the capacitor frame (301) wraps the T+ capacitor copper busbar (304), the insulating paper (305) and the T-insulating copper busbar (306).

6. The non-standard motor controller for a vehicle according to claim 3, characterized in that: The capacitor retaining wall (302) electrically isolates the T+ capacitor copper busbar (304) from the T- capacitor copper busbar (304), and the insulating paper (305) electrically isolates the T+ capacitor copper busbar (304) from the T- insulating copper busbar. The three are pressed together to form a laminated copper busbar capacitor copper busbar assembly.

7. The non-standard motor controller for a vehicle according to claim 3, characterized in that: The T+ capacitor copper busbar (304) and the T-insulated copper busbar (306) are respectively connected to the first positive electrode connection copper column (104), the negative electrode connection copper column (105) and the second positive electrode connection copper column (106) by laser welding. Before the fixing screws (2) and the laser-welded T+ capacitor copper busbar (304) and the T-capacitor copper busbar (304) are screwed, the power module mechanism (1) and the capacitor module mechanism (3) are separated.

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