Integrated structure of extended range generator controller

Abstract

The utility model relates to an integrated structure of an extended range generator controller, which comprises a controller box body and a function module, the function module is arranged in the controller box body, the integrated structure further comprises a radiator and an annular connecting end, the connecting end is fixed at the bottom of the controller box body and is matched with a motor shell, and the radiator is fixed at the bottom of the controller box body. One side, far away from the controller box body, of the connecting end is connected with a motor shell; an IGBT heat dissipation area is arranged in the controller box body, the radiator is fixed in the IGBT heat dissipation area, and a motor oil cooling channel is arranged at the bottom, close to the controller box body, of the connecting end. Compared with the prior art, the utility model has the advantages of high integration level, good heat dissipation effect and the like.

Description

TECHNICAL FIELD

[0001] The utility model relates to the field of automobile controller structure especially is related to a kind of integrated structure of range extending generator controller. BACKGROUND

[0002] With the high-speed development of new energy automobile industry, the competition of industry is increasingly fierce, and high-performance low-cost new energy vehicles become the target of vehicle manufacturers. As the core components of new energy vehicles, the cost of motor and its controller directly affects the achievement rate of vehicle cost target. The design scheme of small size and integration of electric drive system is the key direction to reduce material cost and manufacturing cost.

[0003] For early electric drive system, motor and its controller mostly adopt separate design scheme, and the components of a set of motor and controller are more, and the assembly process is more complex, which does not meet the miniaturization and integration design trend of low-cost new energy vehicles. In addition, for the range extending generator system popular in recent years, due to the installation position beside the engine, the environment temperature is higher, so that the controller system has to bear the abnormal high temperature baking, which brings great challenge to the electronic components inside the controller.

[0004] In summary, the existing generator controller and generator shell structure are separate structure, which is not conducive to the miniaturization of automobile electric drive system, and the heat generated by the engine also has adverse effect on the use of the controller. Therefore, a kind of integrated structure of range extending generator controller with high integration and good heat dissipation effect is needed. UTILITY MODEL CONTENT

[0005] The utility model aims at overcoming the defects of the existing technology, such as the separate structure of electric drive system, which is not conducive to miniaturization, and the heat generated by the generator, which has adverse effect on the operation of the controller, and provides a kind of integrated structure of range extending generator controller with high integration and good heat dissipation effect.

[0006] The purpose of the utility model can be realized by the following technical scheme:

[0007] A kind of integrated structure of range extending generator controller, including controller box and function module, the function module is installed in controller box, the structure further includes radiator and circular ring connection end, the connection end is fixed at the bottom of controller box, and is matched with motor shell, the side of the connection end away from controller box is connected with motor shell;IGBT heat dissipation area is arranged in the controller box, the radiator is fixed in IGBT heat dissipation area, and motor oil cooling channel is arranged in the bottom of the connection end close to controller box.

[0008] Preferably, the outer wall of the controller housing is provided with a suspension mounting component, and the suspension mounting component is connected with cross-shaped reinforcing ribs around its perimeter.

[0009] Preferably, the cross-shaped reinforcing rib includes a horizontal plate, an X-shaped plate, and an inclined plate;

[0010] One end of the horizontal plate is connected to the suspension mounting component and is parallel to the end face of the connecting end. The X-shaped plate is connected to the suspension mounting component and is located between two parallel horizontal plates. One end of the inclined plate is connected to the horizontal plate, and the other end is connected to the connecting end.

[0011] Preferably, the inner side of the side wall of the controller housing where the suspension mounting component is located is provided with a rectangular array of reinforcing ribs.

[0012] Preferably, the rectangular array of reinforcing ribs includes a first rib and a plurality of second ribs, the first rib being parallel to the side wall of the controller housing, the second ribs being located between the side wall and the first rib, and each of the second ribs being parallel to the other.

[0013] Preferably, the connection end has a motor bearing chamber near the bottom of the controller housing, and the motor bearing chamber is located inside the connection end.

[0014] Preferably, the connection end is provided with a motor rotating wiring harness mounting component near the bottom of the controller housing, and the motor rotating wiring harness mounting component is located inside the connection end.

[0015] Preferably, the functional module includes a high-voltage wiring harness, a filter, a thin-film capacitor, an IGBT module, a busbar, and a low-voltage wiring harness connected in sequence, with the IGBT module fixed on a heat sink.

[0016] Preferably, a sealing ring is provided between the heat sink and the IGBT module, and a sealing groove is provided on the heat dissipation area of ​​the IGBT, with the sealing ring installed in the sealing groove.

[0017] Preferably, the filter comprises a first-stage Y capacitor, a second-stage magnetic ring, a third-stage Y capacitor, a fourth-stage magnetic ring, a fifth-stage Y capacitor, and a sixth-stage magnetic ring connected in sequence.

[0018] Compared with the prior art, the present invention has the following advantages:

[0019] (1) This solution installs the functional modules of the controller inside the controller box. A circular connection end that matches the motor housing is set at the bottom of the controller box. The rear end cover of the motor housing and the control box are integrated into a single structure. The controller and the motor are integrated together through the connection end. In addition, a heat sink is installed in the IGBT heat dissipation area of ​​the controller box, and a motor oil cooling channel is integrated at the bottom of the connection end. The controller is cooled down by the motor oil cooling channel in conjunction with the heat sink.

[0020] By incorporating a connection end at the bottom of the controller housing that mates with the motor housing, the controller and motor are connected via this connection end. This reduces the manufacturing and processing costs of motor components, simplifies the assembly of the automotive drive system, reduces the weight of the overall drive system, and meets the low-cost requirements for vehicle integration and miniaturization. In addition to a traditional radiator inside the controller, a motor oil-cooling channel is integrated at the bottom of the connection end near the controller. This achieves dual-layer heat dissipation of the controller housing using both liquid and oil cooling, significantly reducing the thermal impact of the motor on the controller, ensuring that the internal temperature of the controller remains within a controllable range, and improving the reliability and stability of the overall drive system.

[0021] (2) This solution integrates a suspension mounting component on one side of the controller housing, and sets cross-shaped reinforcing ribs around the suspension mounting component. Inside the controller housing, near the suspension mounting component, a rectangular array of reinforcing ribs is set, thereby achieving high strength and high rigidity mechanical properties for the controller housing.

[0022] (3) This solution also integrates the motor bearing chamber and the motor resolver wiring harness mounting component inside the connection end, so that the connection end can be directly installed on the motor housing as the rear end cover of the motor housing, which improves the space utilization of the assembly drive system and improves the integration of the assembly.

[0023] (4) The filter in this scheme adopts the CLCLCL arrangement scheme, which integrates three-stage magnetic rings and Y capacitors in thin film capacitors in a limited space. It has a high filtering level and can enable the controller to have a high EMC filtering effect. Attached Figure Description

[0024] Figure 1 A front view of the integrated controller structure provided by this utility model;

[0025] Figure 2 A schematic diagram of the back of the integrated controller structure provided by this utility model;

[0026] Figure 3 This is a schematic diagram of the outer side of the controller housing provided by this utility model;

[0027] Figure 4 This is a schematic diagram of the internal structure of the controller housing provided by this utility model;

[0028] Figure 5 A schematic diagram of the integrated cooling channel structure of the controller provided by this utility model;

[0029] Figure 6 A schematic diagram of the filter structure provided by this utility model;

[0030] In the diagram: 1. Controller housing; 2. Connection terminal; 3. Functional module; 11. IGBT heat dissipation area; 12. Suspension mounting component; 13. Cross-shaped reinforcing rib; 14. Rectangular array reinforcing rib; 21. Motor oil cooling channel; 22. Motor bearing chamber; 23. Motor rotating wiring harness mounting component; 31. High-voltage wiring harness; 32. Filter; 33. Film capacitor; 34. IGBT module; 35. Busbar; 36. Low-voltage wiring harness; 131. Horizontal plate; 132. X-shaped plate; 133. Slanted plate; 141. First rib plate; 142. Second rib plate; 321. First-stage Y capacitor; 322. Second-stage magnetic ring; 323. Third-stage Y capacitor; 324. Fourth-stage magnetic ring; 325. Fifth-stage Y capacitor; 326. Sixth-stage magnetic ring. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0032] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0033] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0034] In the description of this utility model, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the utility model product is in use. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0035] It should be noted that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0036] Furthermore, terms such as "horizontal" and "vertical" do not imply that components must be absolutely horizontal or suspended, but rather that they can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," not that the structure must be completely horizontal, but can be slightly tilted.

[0037] Example 1

[0038] like Figures 1 to 6 As shown, this embodiment provides an integrated structure for a range extender generator controller, including a controller housing 1 and a functional module. The functional module is installed inside the controller housing 1. The structure also includes a heat sink and a circular connecting end 2. The connecting end 2 is fixed to the bottom of the controller housing 1 and cooperates with the motor housing. The side of the connecting end 2 away from the controller housing 1 is connected to the motor housing. An IGBT heat dissipation area is provided inside the controller housing 1, and the heat sink is fixed to the IGBT heat dissipation area 11. A motor oil cooling channel 21 is provided near the bottom of the controller housing 1 on the connecting end 2.

[0039] Working principle: The functional modules of the controller are installed in the controller housing 1. A circular connecting end 2 that mates with the motor housing is set at the bottom of the controller housing 1. The rear end cover of the motor housing is integrated with the control housing 1 into a single structure. The controller and the motor are integrated together through the connecting end 2. In addition, a heat sink is installed in the IGBT heat dissipation area 11 of the controller housing 1, and a motor oil cooling channel 21 is integrated at the bottom of the connecting end 2. The motor oil cooling channel 21, together with the heat sink, dissipates heat and cools the controller.

[0040] By setting a connection end 2 at the bottom of the controller housing 1 to mate with the motor housing, the controller and motor are connected via the connection end 2. This reduces the manufacturing and processing costs of motor components, simplifies the assembly of the automotive drive system, reduces the weight of the overall drive system, and meets the low-cost requirements of vehicle integration and miniaturization. In addition to a traditional radiator inside the controller, a motor oil cooling channel 21 is integrated at the bottom of the connection end 2 near the controller. This achieves dual-layer heat dissipation of the controller housing using both liquid and oil cooling, significantly reducing the thermal impact of the motor on the controller, ensuring that the internal temperature of the controller remains within a controllable range, improving the reliability and stability of the overall drive system, and extending the lifespan of the controller.

[0041] Preferred implementation methods, such asFigure 3 and Figure 4 As shown, a suspension mounting component 12 is provided on the outer wall of the controller housing 1, and a cross-shaped reinforcing rib 13 is connected around the suspension mounting component 12.

[0042] Among them, the cross-shaped reinforcing rib 13 includes a horizontal plate 131, an X-shaped plate 132 and an inclined plate 133;

[0043] One end of the horizontal plate 131 is connected to the suspension mounting piece 12 and is parallel to the end face of the connecting end 2. The X-shaped plate 132 is connected to the suspension mounting piece 12 and is located between the two parallel horizontal plates 131. One end of the inclined plate 133 is connected to the horizontal plate 131 and the other end is connected to the connecting end 2.

[0044] Furthermore, the inner side of the side wall of the controller housing 1, where the suspension mounting component 12 is provided, is provided with a rectangular array of reinforcing ribs 14.

[0045] The rectangular array of reinforcing ribs 14 includes a first rib plate 141 and a plurality of second rib plates 142. The first rib plate 141 is parallel to the side wall of the controller housing 1, and the second rib plates 142 are located between the side wall and the first rib plate 141, and each of the second rib plates 142 is parallel to the other.

[0046] A suspension mount is integrated on one side of the controller housing, and cross-shaped reinforcing ribs are provided around the suspension mount. A rectangular array of reinforcing ribs is provided inside the controller housing near the suspension mount, thereby achieving high strength and high rigidity mechanical properties for the controller housing.

[0047] Preferred implementation methods, such as Figure 3 As shown, a motor bearing chamber 22 is provided at the bottom of the connection end 2 near the controller housing 1, and the motor bearing chamber 22 is located inside the connection end 2.

[0048] Furthermore, a motor rotating wiring harness mounting component 23 is provided at the bottom of the connection end 2 near the controller housing 1, and the motor rotating wiring harness mounting component 23 is located inside the connection end 2.

[0049] The connection end also integrates the motor bearing housing and the motor resolver wiring harness mounting components, allowing the connection end to be directly mounted on the motor housing as the rear end cover of the motor housing. This improves the space utilization of the assembly drive system and enhances the integration of the assembly.

[0050] Specifically, such as Figure 1 As shown, the functional module includes a high-voltage wiring harness 31, a filter 32, a thin-film capacitor 33, an IGBT module 34, a busbar 35, and a low-voltage wiring harness 36 connected in sequence. The IGBT module 34 is fixed on the heat sink.

[0051] A sealing ring is provided between the heat sink and the IGBT module 34, and a sealing groove is provided on the IGBT heat dissipation area 11, with the sealing ring installed in the sealing groove.

[0052] Optionally, as shown in the figure, the filter 32 includes a first-stage Y capacitor 321, a second-stage magnetic ring 322, a third-stage Y capacitor 323, a fourth-stage magnetic ring 324, a fifth-stage Y capacitor 325, and a sixth-stage magnetic ring 326 connected in sequence.

[0053] The filter adopts a CLCLCL arrangement scheme, integrating a three-stage magnetic ring and a Y capacitor from the thin-film capacitor within a limited space. It has a high filtering level, which enables the controller to have a high EMC filtering effect.

[0054] The specific assembly process of the integrated controller structure in this embodiment includes: offline fixing of the Y capacitor in the corresponding slot of the corresponding filter bracket; placing the pins at both ends of the Y capacitor into the clamps leading out from the positive and negative copper busbars and the ground copper busbar respectively, and connecting them using resistance welding; inserting the high-voltage plug into the corresponding slot on the controller housing and tightening it with bolts; placing the offline assembled Y capacitor inside the housing, with the copper busbar overlapping the high-voltage plug; fixing the heat sink to the heat sink mounting point inside the housing with bolts; placing the selected sealing ring in the heat sink sealing groove and then fixing the selected IGBT module onto the heat sink. Position the custom-made film capacitor at the mounting point between the filter and the module, with the input terminal of the film capacitor connected to the output terminal of the filter and the output terminal connected above the input terminal of the IGBT. Use appropriate bolts to fix the IGBT and the corresponding input and output terminals. Place the PCBA board on top of the IGBT and fix it to the IGBT module and the enclosure with the corresponding bolts. Then, solder the pins of the IGBT to the PCBA board. Place the three-phase paper above the IGBT and fix it with bolts. Finally, place the large box cover in the corresponding position of the enclosure and tighten it with bolts in a crisscross pattern.

[0055] The preferred embodiments of this utility model have been described in detail above. It should be understood that those skilled in the art can make numerous modifications and variations based on the concept of this utility model without creative effort. Therefore, all technical solutions that can be obtained by those skilled in the art based on the concept of this utility model through logical analysis, reasoning, or limited experimentation on the basis of existing technology should be within the scope of protection defined by the claims.

Claims

1. An integrated structure for a range extender generator controller, comprising a controller housing (1) and functional modules, wherein the functional modules are installed within the controller housing (1), characterized in that, The structure also includes a heat sink and a circular connecting end (2). The connecting end (2) is fixed to the bottom of the controller housing (1) and cooperates with the motor housing. The side of the connecting end (2) away from the controller housing (1) is connected to the motor housing. The controller housing (1) is provided with an IGBT heat dissipation area. The heat sink is fixed in the IGBT heat dissipation area (11). The connecting end (2) is provided with a motor oil cooling channel (21) near the bottom of the controller housing (1).

2. The integrated structure of a range extender generator controller according to claim 1, characterized in that, The controller housing (1) is provided with a suspension mounting component (12) on its outer side wall, and a cross-shaped reinforcing rib (13) is connected around the suspension mounting component (12).

3. The integrated structure of a range extender generator controller according to claim 2, characterized in that, The cross-shaped reinforcing rib (13) includes a horizontal plate (131), an X-shaped plate (132), and an inclined plate (133); One end of the horizontal plate (131) is connected to the suspension mounting component (12) and is parallel to the end face of the connecting end (2). The X-shaped plate (132) is connected to the suspension mounting component (12) and is located between two parallel horizontal plates (131). One end of the inclined plate (133) is connected to the horizontal plate (131) and the other end is connected to the connecting end (2).

4. The integrated structure of a range extender generator controller according to claim 2, characterized in that, The controller housing (1) has rectangular array-type reinforcing ribs (14) on the inner side of the side wall of the suspension mounting component (12).

5. The integrated structure of a range extender generator controller according to claim 4, characterized in that, The rectangular array of reinforcing ribs (14) includes a first rib plate (141) and a plurality of second rib plates (142). The first rib plate (141) is parallel to the side wall of the controller housing (1). The second rib plates (142) are located between the side wall and the first rib plate (141), and each second rib plate (142) is parallel to the other.

6. The integrated structure of a range extender generator controller according to claim 1, characterized in that, The connection end (2) is provided with a motor bearing chamber (22) near the bottom of the controller housing (1), and the motor bearing chamber (22) is located inside the connection end (2).

7. The integrated structure of a range extender generator controller according to claim 1, characterized in that, The connection end (2) is provided with a motor rotating wire harness mounting component (23) near the bottom of the controller housing (1), and the motor rotating wire harness mounting component (23) is located inside the connection end (2).

8. The integrated structure of a range extender generator controller according to claim 1, characterized in that, The functional module (3) includes a high-voltage wiring harness (31), a filter (32), a thin-film capacitor (33), an IGBT module (34), a busbar (35), and a low-voltage wiring harness (36) connected in sequence. The IGBT module (34) is fixed on the heat sink.

9. The integrated structure of a range extender generator controller according to claim 8, characterized in that, A sealing ring is provided between the heat sink and the IGBT module (34), and a sealing groove is provided on the IGBT heat dissipation area (11), with the sealing ring installed in the sealing groove.

10. The integrated structure of a range extender generator controller according to claim 8, characterized in that, The filter (32) includes a first-stage Y capacitor (321), a second-stage magnetic ring (322), a third-stage Y capacitor (323), a fourth-stage magnetic ring (324), a fifth-stage Y capacitor (325), and a sixth-stage magnetic ring (326) connected in sequence.

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