Filter and motor controller

Abstract

The utility model relates to the technical field of automobile parts, and provides a filter and a motor controller. The filter comprises a common-mode and differential-mode integrated magnet ring, the common-mode and differential-mode integrated magnet ring comprises a common-mode magnet ring and a differential-mode piece inserted in the common-mode magnet ring, and the end face of the differential-mode piece is shrunk inwards relative to the end face of the common-mode magnet ring; the protection box comprises an annular box body and a copper bar through hole, the annular box body surrounds the common mode magnetic ring, the copper bar through hole penetrates through the space between the differential mode piece and the common mode magnetic ring and extends out, and the end face of the copper bar through hole is higher than the end face of the common mode magnetic ring. According to the utility model, through the design that the differential mode piece is inserted into the common mode magnetic ring, an appropriate differential mode piece material / common mode magnetic ring material can be selected according to the differential mode filtering / common mode filtering requirement, and the common-differential mode filtering effect of the filter is improved; the end face of the differential mode piece is shrunk inwards relative to the end face of the common mode magnetic ring, so that the problem of magnetic leakage between the differential mode piece and the common mode magnetic ring can be reduced, and the EMC filtering effect of the filter is improved; and the common-mode and differential-mode integrated magnetic ring is matched with the protection box, so that the whole filter is easy to assemble.

Description

Technical Field

[0001] This utility model relates to the field of automotive parts technology, specifically to filters and motor controllers. Background Technology

[0002] In the filters of motor controllers, common-mode and differential-mode components are critical. Current common-mode and differential-mode components suffer from the following problems:

[0003] Some common-mode and differential-mode components are made of ferrite in one piece, meaning that the common-mode and differential-mode use the same material. This makes it impossible to improve the EMC (Electromagnetic Compatibility) performance of the common-mode or differential-mode components separately, resulting in unsatisfactory filtering performance of the filter.

[0004] Some common-mode and differential-mode components are assembled separately by common-mode magnetic rings and differential-mode plates. Although this can optimize the performance of common-mode and differential-mode components respectively, there is a magnetic leakage problem between the differential-mode plate and the common-mode magnetic ring, which affects the filtering effect of common and differential modes and brings new EMC problems to the filter.

[0005] It should be noted that the information disclosed in the background section above is only used to enhance the understanding of the background of this utility model, and therefore may include information that does not constitute prior art known to those skilled in the art. Utility Model Content

[0006] This invention provides a filter and a motor controller. By inserting a differential mode chip into a common mode magnetic ring, the appropriate differential mode chip material and common mode magnetic ring material can be selected according to the needs of differential mode filtering / common mode filtering, thereby improving the common and differential mode filtering effect of the filter. The end face of the differential mode chip is recessed relative to the end face of the common mode magnetic ring, which can reduce the leakage magnetic problem between the differential mode chip and the common mode magnetic ring and improve the EMC filtering effect of the filter.

[0007] According to one aspect of the present invention, a filter is provided, comprising: a common-mode integrated magnetic ring, including a common-mode magnetic ring and a differential-mode plate inserted in the common-mode magnetic ring, wherein the end face of the differential-mode plate is recessed relative to the end face of the common-mode magnetic ring; and a protective casing, including an annular box body and copper busbar through-holes, wherein the annular box body surrounds the common-mode magnetic ring, the copper busbar through-holes pass through the space between the differential-mode plate and the common-mode magnetic ring and extend outward, and the end face of the copper busbar through-holes is higher than the end face of the common-mode magnetic ring.

[0008] In some embodiments, the end face of the differential mode piece is recessed by 1 mm to 2 mm relative to the end face of the common mode magnetic ring.

[0009] In some embodiments, the annular box includes a base, the base having a first protrusion corresponding to the position of the differential mold piece, the differential mold piece being placed on the first protrusion; the copper busbar is connected to the base and extends out of the base.

[0010] In some embodiments, the first protrusion is formed by an insulating pad.

[0011] In some embodiments, the differential mode sheet and the common mode magnetic ring are bonded together.

[0012] In some embodiments, the filter further includes: a top cover, assembled with the protective case, wherein the top cover and the protective case together limit the common-mode magnetic ring and the differential-mode plate.

[0013] In some embodiments, the upper cover is provided with a second protrusion at the position corresponding to the differential mold piece, and the second protrusion abuts against the differential mold piece; the upper cover is provided with a through hole at the position corresponding to the copper busbar through hole, and the copper busbar through hole passes through the through hole and extends out.

[0014] In some embodiments, the differential mode sheet comprises two pieces, and the copper busbar through-hole comprises three pieces, with the differential mode sheet and the copper busbar through-hole being alternately distributed within the annular region enclosed by the common mode magnetic ring.

[0015] In some embodiments, the common-mode magnetic ring is one of a ferrite magnetic ring, a nanocrystalline magnetic ring, and an amorphous magnetic ring, and / or the differential-mode sheet is one of a ferrite sheet and a silicon iron sheet.

[0016] According to another aspect of the present invention, a motor controller is provided, the motor controller being configured with a filter as described in any of the above embodiments.

[0017] The beneficial effects of this utility model compared with the prior art include at least the following:

[0018] This invention, through the design of inserting a differential-mode chip into a common-mode magnetic ring, allows for the selection of appropriate differential-mode chip / common-mode magnetic ring materials based on the needs of differential-mode / common-mode filtering, thereby improving the filter's differential-mode and common-mode filtering performance. The common-mode magnetic ring can be a ferrite ring, nanocrystalline ring, or amorphous ring; the specific choice depends on the actual situation, selecting low-conductivity or high-conductivity magnetic materials. The differential-mode chip can be a ferrite sheet or a silicon-iron sheet, using a low-conductivity core material to prevent differential-mode current saturation.

[0019] This invention, through the design of the differential mode chip's end face being recessed relative to the common mode magnetic ring's end face, can effectively reduce the magnetic field leakage problem at the end faces of the differential mode chip and the common mode magnetic ring, thereby improving the EMC filtering effect of the filter.

[0020] Furthermore, this invention facilitates the assembly of the filter by using a common-mode integrated magnetic ring in conjunction with the protective housing. The common-mode integrated magnetic ring is placed inside the annular housing of the protective housing, allowing the copper busbar of the housing to pass through the space between the differential mode plate and the common-mode magnetic ring and extend outwards. The end face of the copper busbar through-hole protrudes above the end face of the common-mode magnetic ring to facilitate the placement and wiring of the copper busbar.

[0021] The filter of this invention is suitable for motor controllers in pure electric vehicles, hybrid vehicles, and other types of vehicles, and can significantly improve the working performance of the motor controller.

[0022] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit the present invention. Attached Figure Description

[0023] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments conforming to the present invention and, together with the description, serve to explain the principles of the present invention. It is obvious that the drawings described below are merely some embodiments of the present invention, and those skilled in the art can obtain other drawings based on these drawings without any inventive effort.

[0024] Figure 1 A three-dimensional structural schematic diagram of the filter in an embodiment of this utility model is shown;

[0025] Figure 2 A three-dimensional structural schematic diagram of the integrated magnetic ring with common differential mode is shown in an embodiment of this utility model;

[0026] Figure 3 A three-dimensional structural diagram of the protective box in an embodiment of this utility model is shown;

[0027] Figure 4 The diagram shows a top view of the integrated magnetic ring with common differential mode in an embodiment of this utility model.

[0028] Figure 5 This diagram shows a cross-sectional view of the protective box in an embodiment of the present invention.

[0029] Figure 6 This diagram shows a cross-sectional view of the integrated magnetic ring with common differential mode placed in a protective box in an embodiment of the present invention.

[0030] Figure 7 A three-dimensional structural schematic diagram of the tooling in an embodiment of this utility model is shown;

[0031] Figure 8 This diagram shows a cross-sectional view of the tooling in an embodiment of the present invention.

[0032] Figure 9This diagram shows a cross-sectional view of the integrated magnetic ring with a common differential mode placed in a tooling according to an embodiment of the present invention. Detailed Implementation

[0033] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. However, these exemplary embodiments can be implemented in many forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided to make the present invention more comprehensive and complete, and to fully convey the concept of the exemplary embodiments to those skilled in the art.

[0034] The accompanying drawings are merely illustrative of the present invention and are not necessarily drawn to scale. The same reference numerals in the drawings denote the same or similar structures, and therefore, repeated descriptions of them will be omitted.

[0035] The use of terms such as "first," "second," and similar words in the specific description does not indicate any order, quantity, or importance, but is merely used to distinguish different components. Furthermore, in the description of this utility model, terms such as "upper," "lower," etc., indicate orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings. These are merely for ease of 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. Moreover, in the description of this utility model, when it is said that a device is "connected" to another device, this includes not only direct connections but also indirect connections through other elements.

[0036] It should be noted that, unless otherwise specified, the embodiments of this utility model and the features in different embodiments can be combined with each other.

[0037] Figure 1 The diagram illustrates the three-dimensional structure of the filter in this embodiment of the invention. Figure 2 The diagram illustrates the three-dimensional structure of the common-mode integrated magnetic ring of the filter. Figure 3 The diagram illustrates the three-dimensional structure of the filter housing; combined with Figures 1 to 3 As shown, the filter provided in this embodiment of the present invention includes:

[0038] The common-mode and differential-mode integrated magnetic ring 100 includes a common-mode magnetic ring 110 and a differential-mode piece 120 inserted in the common-mode magnetic ring 110, wherein the end face of the differential-mode piece 120 is recessed relative to the end face of the common-mode magnetic ring 110.

[0039] The protective box 200 includes an annular box body 210 and a copper busbar through hole 220. The annular box body 210 surrounds the common mode magnetic ring 110. The copper busbar through hole 220 passes through the space between the differential mode plate 120 and the common mode magnetic ring 110 and extends out. The end face of the copper busbar through hole 220 is higher than the end face of the common mode magnetic ring 110.

[0040] This invention, through the design of inserting a differential-mode chip 120 into a common-mode magnetic ring 110, allows for the selection of appropriate materials for the differential-mode chip 120 and the common-mode magnetic ring 110 based on the needs of differential-mode / common-mode filtering, thereby improving the filter's differential-mode and common-mode filtering performance. The common-mode magnetic ring 110 can be a ferrite magnetic ring, a nanocrystalline magnetic ring, or an amorphous magnetic ring; specifically, low-conductivity / high-conductivity magnetic materials can be selected according to actual conditions. The differential-mode chip 120 can be a ferrite sheet or a silicon-iron sheet, using a low-conductivity core material to prevent differential-mode current saturation.

[0041] This invention, by designing the end face of the differential mode filter 120 to be recessed relative to the end face of the common mode magnetic ring 110, can effectively reduce the magnetic field leakage problem at the end faces of the differential mode filter 120 and the common mode magnetic ring 110, thereby improving the EMC filtering effect of the filter. It should be noted that... Figure 1 and Figure 2 In the illustration, only the upper end face of the differential mode 120 is shown to be recessed relative to the upper end face of the common mode magnetic ring 110. In the actual product, the lower end face of the differential mode 120 is also recessed relative to the lower end face of the common mode magnetic ring 110, which effectively reduces the magnetic leakage problem between the differential mode 120 and the common mode magnetic ring 110.

[0042] Furthermore, this invention facilitates the assembly of the filter by using a common-mode integrated magnetic ring 100 in conjunction with a protective case 200. The common-mode integrated magnetic ring 100 is placed inside the annular housing 210 of the protective case 200, allowing the copper busbar through-holes 220 of the protective case 200 to pass through the space between the differential mode plate 120 and the common-mode magnetic ring 110 and extend outwards. The end face of the copper busbar through-hole 220 protrudes above the end face of the common-mode magnetic ring 110 to facilitate the placement and wiring of the copper busbars. The number of copper busbar through-holes 220 depends on the configuration of the motor controller to which the filter is applied; for example, the number of copper busbar through-holes 220 can be... Figure 1 and Figure 3 The figure shows three; in other embodiments, the number of copper busbar holes may also be two, four, etc. In the figures of this utility model, it is shown that the differential mode piece 120 includes two pieces, and the copper busbar hole 220 includes three pieces. The differential mode piece 120 and the copper busbar hole 220 are alternately distributed in the annular area enclosed by the common mode magnetic ring 110, thus achieving a reasonable layout.

[0043] The filter of this invention is suitable for motor controllers in pure electric vehicles, hybrid vehicles, and other types of vehicles, and can significantly improve the working performance of the motor controller.

[0044] In some embodiments, refer to Figure 2 As shown, the end face of the differential mode plate 120 is recessed by 1mm to 2mm relative to the end face of the common mode magnetic ring 110. This design can effectively reduce the magnetic field leakage problem at the end faces of the differential mode plate 120 and the common mode magnetic ring 110.

[0045] In some embodiments, the differential mold plate 120 and the common mold magnetic ring 110 are bonded together. That is, the differential mold plate 120 and the common mold magnetic ring 110 are fixed together by dispensing or potting adhesive. Figure 4 The diagram illustrates the top view of the integrated common-mode magnetic ring, combined with... Figure 2 and Figure 4 As shown, after the differential mode piece 120 is inserted into the common mode magnetic ring 110, at the gap between the differential mode piece 120 and the common mode magnetic ring 110 ( Figure 4 Apply glue or potting to the area marked by the dashed box in the middle to fix the differential mold piece 120 and the common mold magnetic ring 110.

[0046] In some embodiments, the differential mode plate 120 and the common mode magnetic ring 110 may not be glued / potted, but are fixed by the cooperation of the protective box 200 and the top cover (not specifically shown in the figure). Specifically, the filter also includes a top cover, which is assembled with the protective box 200 to jointly limit the common mode magnetic ring 110 and the differential mode plate 120.

[0047] Figure 5 The cross-sectional view of the protective box is shown. Figure 6 The diagram illustrates the cross-sectional structure of the common-mode integrated magnetic ring placed within the protective casing; combined with Figure 1 , Figure 5 and Figure 6 As shown, in some embodiments, the annular box 210 includes a base 211, and the base 211 has a first protrusion 212 at the position corresponding to the differential mode piece 120, on which the differential mode piece 120 is placed. By setting the first protrusion 212 on the base 211 of the protective box 200, the lower end face of the differential mode piece 120 is recessed relative to the lower end face of the common mode magnetic ring 110.

[0048] In addition, the copper busbar through-hole 220 is connected to the base 211 and extends out of the base 211.

[0049] In some embodiments, the first protrusion 212 is formed by an insulating pad. Thus, by increasing / decreasing the insulating pad, the thickness of the first protrusion 212 can be changed, and the inward dimension of the differential plate 120 can be flexibly controlled.

[0050] The differential mold plate 120 and the common mold magnetic ring 110 can be fixed by dispensing / potting glue, or by being jointly fixed by the top cover and the protective box 200. In the embodiment including the top cover, a second protrusion can be provided at the position of the top cover corresponding to the differential mold plate 120, and the second protrusion abuts against the differential mold plate 120; the second protrusion ensures that the upper end face of the differential mold plate 120 is recessed relative to the upper end face of the common mold magnetic ring 110. In addition, a through hole is provided at the position of the top cover corresponding to the copper busbar through hole 220, and the copper busbar through hole 220 passes through the through hole and extends out, which facilitates the installation and wiring of the copper busbar.

[0051] In addition to the inward retraction of the differential mold piece 120 through the protective box 200, in some embodiments, the inward retraction of the differential mold piece 120 can also be achieved through tooling. Figure 7 The diagram illustrates the three-dimensional structure of the tooling. Figure 8 The cross-sectional structure of the tooling is shown. Figure 9 The diagram illustrates the cross-sectional structure of the common-mode integrated magnetic ring placed in the tooling; combined with Figure 1 and Figure 2 , Figures 7 to 9 As shown, the fixture 300 is adapted to the common-differential mold integrated magnetic ring 100, and a protruding structure 310 is provided at the position of the differential mold piece 120 on the fixture 300. During assembly, the common-differential mold magnetic ring 110 and the differential mold piece 120 are placed on the fixture, and the common-differential mold magnetic ring 110 and the differential mold piece 120 can be positioned with the help of the fixture. The differential mold piece 120 is placed on the protruding structure 310 to ensure that the lower end face of the differential mold piece 120 is recessed relative to the lower end face of the common-differential mold magnetic ring 110. Then, the differential mold piece 120 and the common-differential mold magnetic ring 110 are fixed by dispensing / potting glue. After fixing, it is removed to obtain the common-differential mold integrated magnetic ring 100. Finally, the common-differential mold integrated magnetic ring 100 is placed into the protective box 200 to complete the assembly.

[0052] This invention also provides a motor controller equipped with a filter as described in any of the above embodiments. The filter of this invention is suitable for motor controllers in pure electric vehicles, hybrid vehicles, and other similar vehicles, and can significantly improve the performance of the motor controller.

[0053] The above description, in conjunction with specific preferred embodiments, provides a further detailed explanation of the present invention. It should not be construed that the specific implementation of the present invention is limited to these descriptions. For those skilled in the art, various simple deductions or substitutions can be made without departing from the concept of the present invention, and all such modifications and substitutions should be considered within the protection scope of the present invention.

Claims

1. A filter, characterized in that, include: A common-mode integrated magnetic ring includes a common-mode magnetic ring and a differential-mode piece inserted in the common-mode magnetic ring, wherein the end face of the differential-mode piece is recessed relative to the end face of the common-mode magnetic ring; The protective case includes an annular box body and a copper busbar through hole. The annular box body surrounds the common mode magnetic ring. The copper busbar through hole passes through the space between the differential mode plate and the common mode magnetic ring and extends out. The end face of the copper busbar through hole is higher than the end face of the common mode magnetic ring.

2. The filter as described in claim 1, characterized in that, The end face of the differential mode piece is recessed by 1mm to 2mm relative to the end face of the common mode magnetic ring.

3. The filter as described in claim 1, characterized in that, The annular box includes a base, and the base has a first protrusion corresponding to the position of the differential mold piece, and the differential mold piece is placed on the first protrusion; The copper busbar is perforated and connected to the base, extending out of the base.

4. The filter as described in claim 3, characterized in that, The first protrusion is formed by an insulating pad.

5. The filter as described in claim 1, characterized in that, The differential mode sheet and the common mode magnetic ring are bonded together.

6. The filter as described in claim 1, characterized in that, Also includes: The top cover is assembled with the protective box, and the top cover and the protective box together limit the common mode magnetic ring and the differential mode piece.

7. The filter as described in claim 6, characterized in that, The upper cover is provided with a second protrusion at the position corresponding to the differential mold piece, and the second protrusion abuts against the differential mold piece; The upper cover is provided with a through hole at the position corresponding to the copper busbar through hole, and the copper busbar through hole passes through the through hole and extends out.

8. The filter as described in claim 1, characterized in that, The differential mode sheet comprises two pieces, and the copper busbar through-hole comprises three pieces. The differential mode sheet and the copper busbar through-hole are alternately distributed within the annular area enclosed by the common mode magnetic ring.

9. The filter as described in claim 1, characterized in that, The common-mode magnetic ring is one of ferrite magnetic ring, nanocrystalline magnetic ring, and amorphous magnetic ring, and / or the differential-mode sheet is one of ferrite sheet and iron-silicon sheet.

10. A motor controller, characterized in that, The motor controller is equipped with a filter as described in any one of claims 1-9.

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