Single-motor controller system for new energy automobile
The modular design of the single-motor controller system solves the problems of large size and complexity of traditional motor controller systems, achieving compactness, lightweight design, and rich expansion interfaces. It is suitable for new energy vehicles and improves the flexibility and reliability of motor control.
Patent Information
- Application Number
- CN202520219536.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-02-12
- Publication Date
- 2025-11-21
- Estimated Expiration
- 2035-02-12
AI Technical Summary
Traditional motor controller systems in new energy vehicles, due to their complexity and large size, result in bulky machine appearance, non-compact spatial layout, increased energy loss, and inconvenient installation and maintenance.
A single-motor controller system for new energy vehicles was designed, including a control board module, a drive board module, a bus capacitor and power device module, a discharge and Y capacitor board module, and a motor module. Through modular design, it provides expansion interfaces and a compact and lightweight structure, adapts to 500V and 800V battery systems, reduces wiring harness failures, and achieves internal wireless wiring harness processing.
It achieves a compact and lightweight motor controller system, provides rich expansion interfaces, reduces energy loss and installation and maintenance difficulty, is suitable for different vehicle models, and is compatible with 500V and 800V battery systems, improving the flexibility and reliability of motor control.
Smart Images
Figure CN223584064U_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The utility model belongs to single motor controller system technical field relates to a single motor controller system for new energy automobile. BACKGROUND
[0002] In the field of new energy vehicles, motor controllers play a crucial role, and they are the core source of power for new energy vehicles. By precisely regulating current, voltage and other parameters, they provide stable and efficient drive for the motor, thus directly determining the power performance of new energy vehicles, such as acceleration ability, maximum speed, etc. However, traditional motor controllers are generally installed in the assembly of new energy vehicles. This assembly usually integrates a variety of complex components and systems, and is a relatively large and comprehensive whole. For some machines that only require small or medium power and have relatively simple structures, if they are equipped with new energy vehicle assemblies, they will face many problems. On the one hand, due to the complexity and large size of the assembly, these machines will appear extremely bulky in appearance and space layout, destroying the simplicity and compactness of the whole; on the other hand, in the actual operation process, it may cause unnecessary energy loss and cost increase, and also bring inconvenience to installation, maintenance and other operations. SUMMARY
[0003] To solve the problems in the background art, the utility model provides a single motor controller system for new energy vehicles.
[0004] To achieve the above purpose, the utility model adopts the following technical scheme:
[0005] A single motor controller system for new energy vehicles, comprising: a control board module, a drive board module, a bus capacitor and power device module, a discharge and Y capacitor board module, and a motor module.
[0006] The output end of the control board module is connected with the input end of the drive board module, the output end of the drive board module is connected with the input end of the bus capacitor and power device module, the output end of the bus capacitor and power device module is connected with the motor module, and the output end of the discharge and Y capacitor board module is connected with the input end of the bus capacitor and power device module.
[0007] Further, the control board module comprises: an external interface module, a BUCK power supply module, a CAN transceiver chip module, an IO expansion module, a delay power-down module, a motor temperature sampling module, an MCU module, an overcurrent protection circuit module, a Hall current sampling module, and a PWM port.
[0008] The external interface module is connected with the BUCK power module, the CAN transceiver chip module, the IO expansion module, the delay power-down module and the motor temperature sampling module respectively, and the MCU module is connected with the CAN transceiver chip module, the IO expansion module and the delay power-down module respectively; the MCU module is connected with the output end of the BUCK module, the output end of the motor temperature sampling module, the output end of the overcurrent protection circuit module and the output end of the Hall current sampling module, and the output end of the Hall current sampling module is connected with the input end of the overcurrent protection circuit;
[0009] The PWM port outputs a PWM signal, and the control board module is the core of the controller system, wherein the control board module is responsible for the calculation required for controlling the motor module, receives the amplified current signal and the decoded rotary variable signal, and sends a PWM signal to the driving board module after calculation.
[0010] Further, the PWM port is connected with the driving board module.
[0011] The driving board module comprises an isolation driving optocoupler module, a battery power port, a flyback power module and a fault signal port.
[0012] The output end of the PWM port is connected with the isolation driving optocoupler module, the MCU module of the control board module is connected with the input end of the battery power port, the output end of the battery power port is connected with the input end of the flyback power module, the output end of the flyback power module is connected with the isolation driving optocoupler module, and the fault signal port of the isolation driving optocoupler module is connected with the control board module.
[0013] The driving board module provides driving current for the system through the isolation driving optocoupler module.
[0014] Further, the bus capacitor and power device module comprise a positive bus port, a negative bus port, a U-phase port, a V-phase port, a W-phase port, a power capacitor and an IGBT module.
[0015] The output end of the isolation driving optocoupler module is connected with the input end of the IGBT module, the output end of the positive bus port and the output end of the negative bus port are connected with the input end of the IGBT module, the output end of the IGBT module is connected with the U-phase port, the V-phase port and the W-phase port, one end of the power capacitor is connected between the positive bus port and the IGBT module, and the other end of the power capacitor is connected between the negative bus port and the IGBT module.
[0016] The IGBT module integrates six single switch tubes, i.e., six MOS tubes are connected with each other, and the U-phase port, the V-phase port and the W-phase port usually refer to three phases of three-phase alternating current.
[0017] The power capacitor can filter most of the alternating current components of the IGBT module when switching, and can absorb the peak voltage on the bus and the high pulse current on the bus.
[0018] Further, the discharge and Y capacitor plate module comprises a discharge resistor, a first Y capacitor, a second Y capacitor, a shell ground;
[0019] One end of the discharge resistor is connected with the positive bus port and the first Y capacitor, and the other end of the discharge resistor is connected with the negative bus port and the second Y capacitor, and the shell ground is connected between the first Y capacitor and the second Y capacitor;
[0020] The discharge and Y capacitor plate module can consume the electricity of the bus in 3 minutes, so as to restore it to an electrically neutral state.
[0021] Compared with the prior art, the utility model has the following beneficial effects:
[0022] Compared with the traditional motor controller system, the motor controller system of the utility model expands some extended interfaces which can be used independently of the new energy vehicle controller, such as sampling of external analog quantity, output control of high and low levels, input control of high and low levels, and circuits capable of driving external relays, throttle power supply and the like.
[0023] The controller is small and light in weight, and is internally wire harness-free, so that the faults caused by wire harnesses can be reduced, and the controller is suitable for 500V and 800V new energy automobile battery systems. BRIEF DESCRIPTION OF DRAWINGS
[0024] Figure 1 is a single motor controller system structure block diagram for a new energy automobile according to the utility model;
[0025] Figure 2 is a single motor controller system circuit topology diagram for a new energy automobile according to the utility model;
[0026] Figure 3 is a control board module schematic view according to the utility model;
[0027] Figure 4 is a drive board module schematic view according to the utility model;
[0028] Figure 5 is a bus capacitor and power device module schematic view according to the utility model;
[0029] Figure 6 is a discharge and Y capacitor plate module view according to the utility model. DETAILED DESCRIPTION
[0030] Clearly and completely describe the technical scheme in the embodiments of the utility model with the drawings in the embodiments of the utility model, obviously, the described embodiments are only some embodiments of the utility model, not all embodiments. Based on the embodiments in the utility model, all other embodiments obtained by the person skilled in the art without creative labor belong to the scope of the utility model protection.
[0031] As Figures 1-6 Indicated, the utility model adopts technical schemes as follows: a single motor controller system for new energy automobile, including: control board module, drive board module, bus capacitor and power device module, discharge and Y capacitor board module, motor module.
[0032] The output end of the control board module is connected with the input end of the drive board module, the output end of the drive board module is connected with the input end of the bus capacitor and power device module, the output end of the bus capacitor and power device module is connected with the motor module, and the output end of the discharge and Y capacitor board module is connected with the input end of the bus capacitor and power device module.
[0033] Further, the control board module comprises: an external interface module, a BUCK power module, a CAN transceiver chip module, an IO expansion module, a delay power-down module, a motor temperature sampling module, an MCU module, an overcurrent protection circuit module, a Hall current sampling module and a PWM port.
[0034] The external interface module is connected with the BUCK power module, the CAN transceiver chip module, the IO expansion module, the delay power-down module and the motor temperature sampling module, and the MCU module is connected with the CAN transceiver chip module, the IO expansion module and the delay power-down module.
[0035] The PWM port outputs a PWM signal, and the drive board module is connected with the PWM port.
[0036] The control board module is the core of the controller system, wherein the control board module is responsible for the calculation required for motor control, the control board module receives the current signal amplified by the operational amplifier on the receiving board and the decoded rotary variable signal, sends a PWM signal to the drive board after calculation, and the drive board controls the switching of the IGBT module through the PWM signal, thereby controlling the motor.
[0037] The control board module is also configured with an external interface module, which can receive external analog signals, judge high and low levels, control relays, and control external devices or receive signals through the external interface module. The control board module is also equipped with a new energy vehicle delay power-off function, which can delay the power-off of the vehicle for a period of time after the driver turns the key. At the same time, the control board module is also equipped with a voltage reduction function for the battery voltage to provide power to external and internal power supplies.
[0038] The drive board module includes an isolation drive optocoupler module, a battery power supply port, a flyback power supply module, and a fault signal port.
[0039] The output end of the PWM port is connected with the isolation drive optocoupler module, the MCU module of the control board module is connected with the input end of the battery power supply port, the output end of the battery power supply port is connected with the input end of the flyback power supply module, the output end of the flyback power supply module is connected with the isolation drive optocoupler module, and the fault signal port of the isolation drive optocoupler module is connected with the control board module.
[0040] The isolation drive optocoupler module on the drive board module can provide driving current for the IGBT module. Because the voltage and current of the PWM signal output by the control board module are not enough to drive the IGBT module, the isolation drive optocoupler module is needed to provide voltage and current. In this way, the stable operation of the IGBT module can be ensured, otherwise the IGBT module will enter the amplification zone in the switching state, which will cause the IGBT module to be damaged due to excessive loss. The drive board module also has an operational amplifier that can amplify the voltage signal of the temperature sensor in the IGBT module and send it to the control board module for temperature judgment of the IGBT module. At the same time, the power supply required by the isolation drive optocoupler module is provided by the flyback power supply module. The flyback power supply module can stably provide the voltage and current required by the six units of the IGBT.
[0041] The bus capacitor and power device module include a positive bus port, a negative bus port, a U-phase port, a V-phase port, a W-phase port, a power capacitor, and an IGBT module.
[0042] The output end of the isolation drive optocoupler module is connected with the input end of the IGBT module, the output end of the positive bus port and the output end of the negative bus port are connected with the input end of the IGBT module, the output end of the IGBT module is connected with the U-phase port, the V-phase port, and the W-phase port, one end of the power capacitor is connected between the positive bus port and the IGBT module, and the other end of the power capacitor is connected between the negative bus port and the IGBT module.
[0043] The IGBT module integrates six single-unit switching tubes, i.e., six MOS tubes connected with each other. The U-phase port, the V-phase port and the W-phase port usually refer to three phases of three-phase alternating current.
[0044] The power capacitor can filter most of the alternating components of the IGBT module during switching, absorb the peak voltage on the bus, prevent the IGBT module from being damaged due to the peak voltage, and absorb the high pulse current on the bus to prevent its impact on the control board module.
[0045] The discharge and Y capacitor board module includes a discharge resistor, a first Y capacitor, a second Y capacitor and a shell ground.
[0046] One end of the discharge resistor is connected with the positive bus port and the first Y capacitor, and the other end of the discharge resistor is connected with the negative bus port and the second Y capacitor, and the shell ground is connected between the first Y capacitor and the second Y capacitor.
[0047] The discharge and Y capacitor board module can consume the electricity of the bus within 3 minutes to restore it to an electrically inactive state, preventing maintenance personnel from being electrically shocked due to accidental touch during disassembly. The first Y capacitor and the second Y capacitor can reduce high-frequency noise on the bus and suppress common-mode interference.
[0048] The control board module is responsible for external communication, current acquisition and output, and control of the drive board module. The drive board module controls the IGBT module, which outputs corresponding current. The current is sampled by the Hall current sampling module to output a voltage signal feedback to the control board module for receiving and analysis. The control board module outputs corresponding control signals to the drive board module, and the cycle is repeated to control the motor module. The power capacitor is placed between the IGBT module and the bus to filter the ripple generated during the operation of the IGBT module, suppress the peak voltage and avoid damage to the IGBT module. The discharge and Y capacitor board module can discharge high-voltage electricity after the system is powered off to quickly enter the safe operation stage. The first Y capacitor and the second Y capacitor can filter interference signals on the bus.
[0049] In this scheme, many different vehicle models on the market are applicable, from heavy trucks to light trucks and agricultural machinery. Due to its small size and light weight, it can be placed above the motor to form a motor and electronic control two-in-one, and it can be mounted alone on the vehicle. This can be used as an auxiliary motor controller for heavy trucks, or as a motor controller for agricultural machinery.
[0050] Compared with the traditional new energy vehicle assembly, the controller system can be used independently of the new energy vehicle controller, has rich expansion interfaces, can collect external signal analog quantities, external high and low levels, and can control external high and low levels and relays, and also has a power supply that can supply power to the outside.
[0051] Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions recorded in the foregoing embodiments or make equivalent replacement to part of the technical features, and any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the utility model shall be included in the protection scope of the utility model.
Claims
1. A single-motor controller system for new energy vehicles, characterized in that, It includes: control board module, drive board module, bus capacitor and power device module, discharge and Y capacitor board module, and motor module; The output terminal of the control board module is connected to the input terminal of the drive board module, the output terminal of the drive board module is connected to the input terminal of the bus capacitor and power device module, the output terminal of the bus capacitor and power device module is connected to the motor module, and the output terminal of the discharge and Y capacitor board module is connected to the input terminal of the bus capacitor and power device module.
2. The single-motor controller system for new energy vehicles according to claim 1, characterized in that, The control board module includes: an external interface module, a BUCK power supply module, a CAN transceiver chip module, an IO expansion module, a delayed power-down module, a motor temperature sampling module, an MCU module, an overcurrent protection circuit module, a Hall current sampling module, and a PWM port; The external interface module is connected to the BUCK power module, CAN transceiver chip module, IO expansion module, delayed power-down module, and motor temperature sampling module, respectively. The MCU module is connected to the CAN transceiver chip module, IO expansion module, and delayed power-down module, respectively. The MCU module is connected to the output terminal of the BUCK module, the output terminal of the motor temperature sampling module, the output terminal of the overcurrent protection circuit module, and the output terminal of the Hall current sampling module, respectively. The output terminal of the Hall current sampling module is connected to the input terminal of the overcurrent protection circuit. The PWM port outputs a PWM signal. The control board module receives the current signal amplified by the operational amplifier and the decoded resolver signal, and then calculates and outputs the PWM signal.
3. The single-motor controller system for new energy vehicles according to claim 2, characterized in that, The PWM port is connected to a driver board module; The driver board module includes an isolation driver optocoupler module, a battery power port, a flyback power supply module, and a fault signal port. The output of the PWM port is connected to the isolation drive optocoupler module, the MCU module of the control board module is connected to the input of the battery power port, the output of the battery power port is connected to the input of the flyback power module, the output of the flyback power module is connected to the isolation drive optocoupler module, and the fault signal port of the isolation drive optocoupler module is connected to the control board module.
4. A single-motor controller system for new energy vehicles according to claim 3, characterized in that, The bus capacitor and power device module includes a positive bus port, a negative bus port, a U-phase port, a V-phase port, a W-phase port, a power capacitor, and an IGBT module; The output of the isolation drive optocoupler module is connected to the IGBT module. The output of the positive bus port and the output of the negative bus port are connected to the input of the IGBT module. The output of the IGBT module is connected to the U-phase port, V-phase port, and W-phase port. One end of the power capacitor is connected between the positive bus port and the IGBT module, and the other end of the power capacitor is connected between the negative bus port and the IGBT module. The IGBT module integrates six switching transistors, which are interconnected. The U-phase port, V-phase port, and W-phase port refer to the three phases of the three-phase AC power. The power capacitor filters out the AC component of the IGBT module during switching and can absorb peak voltage and high pulse current on the bus.
5. A single-motor controller system for new energy vehicles according to claim 4, characterized in that, The discharge and Y capacitor board module includes a discharge resistor, a first Y capacitor, a second Y capacitor, and a casing ground. One end of the discharge resistor is connected to the positive bus port and the first Y capacitor, and the other end of the discharge resistor is connected to the negative bus port and the second Y capacitor. The casing ground is connected between the first Y capacitor and the second Y capacitor.