Motor controller and vehicle

Abstract

The motor controller comprises a shell, a motor control unit and a power distribution unit, the shell comprises an upper shell body and a lower shell body which are independently formed and connected, the motor control unit is arranged on the lower shell body, and the motor control unit is suitable for being electrically connected with a motor and used for controlling the motor to work. The power distribution unit is arranged on the upper shell and comprises a power distribution base and a power distribution connector, the power distribution base is suitable for being electrically connected with an external power supply device, the power distribution connector is suitable for being electrically connected with an external power utilization device, and the power distribution base is electrically connected with the power distribution connector and the motor control unit. According to the motor controller of the utility model, the motor control and distribution box functions are integrated, the integration level of the motor controller can be improved so as to save the occupied installation space, and in addition, the installation difficulty of the motor control unit and the distribution unit can be well reduced so as to improve the assembly efficiency of the motor controller.

Description

TECHNICAL FIELD

[0001] The utility model relates to motor control technical field especially is related to a kind of motor controller and vehicle. BACKGROUND

[0002] With the increasingly serious pollution problem and energy loss problem, electric vehicles gradually become market new star, and it is found in the development process of electric vehicle that the space layout inside whole vehicle is increasingly compact, and the volume requirement of motor controller is increasingly strict under the premise of guaranteeing its performance, which is important component of electric vehicle.Meanwhile, power distribution box needs to be equipped in electric vehicle, resulting in that larger installation space needs to be reserved in electric vehicle. SUMMARY

[0003] The utility model discloses a motor controller, and the motor controller has the advantages of high integration level, compact structure and high assembly efficiency.

[0004] According to the motor controller of the utility model first aspect embodiment, including: shell, including the upper shell and lower shell that are independently formed and connected respectively;Motor control unit, be located in the lower shell, the motor control unit is suitable for with motor electric connection and is used for controlling motor work;Power distribution unit, be located in the upper shell, the power distribution unit includes power distribution base and power distribution connector, the power distribution base is suitable for with external power supply device electric connection, the power distribution connector is suitable for with external electric device electric connection, the power distribution base and the power distribution connector and the motor control unit are all electric connection.

[0005] According to the motor controller of the utility model first aspect embodiment, by setting power distribution base and power distribution connector, motor controller provides voltage to motor control unit at the same time, and voltage is provided to external electric device, that is, motor controller integrates motor control and power distribution box function, can improve the integration level of motor controller, to save occupied installation space.In addition, the installation difficulty of motor control unit and power distribution unit can be preferably reduced, to improve the assembly efficiency of motor controller.

[0006] According to some embodiments of the utility model, the motor controller further includes a control board assembly electrically connected to the motor control unit, the upper shell forms a first installation cavity open towards the lower shell, the power distribution unit is arranged in the first installation cavity, and the control board assembly is arranged at the opening of the first installation cavity, and the control board assembly is used to fix the power distribution unit in the first installation cavity.

[0007] According to some embodiments of the utility model, the control board assembly includes a control board, a fixed plate and a shielding plate, the fixed plate is fixed at the opening of the first installation cavity and is used for fixing the power distribution unit in the first installation cavity, the shielding plate is located on the side of the fixed plate away from the power distribution unit, and the shielding plate and the fixed plate define a second installation cavity for installing the control board.

[0008] According to some embodiments of the utility model, the motor controller further includes a connecting copper bar, the power distribution unit is electrically connected with the motor control unit through the connecting copper bar, a first avoiding opening is defined between the control board assembly and the upper shell and communicates with the first installation cavity, one end of the connecting copper bar connected with the power distribution unit is located in the first installation cavity, and the other end of the connecting copper bar extends out of the first installation cavity through the first avoiding opening.

[0009] According to some embodiments of the utility model, the power distribution connector includes a power distribution plug and a plurality of connecting terminals electrically connected with the power distribution plug, the connecting terminals are electrically connected with the power distribution base, and the power distribution plug extends out of the shell.

[0010] According to some embodiments of the utility model, the power distribution unit further includes a filter, and the power distribution base is electrically connected with the motor control unit through the filter.

[0011] According to some embodiments of the utility model, the lower shell has a third installation cavity open towards the upper shell and a fourth installation cavity open towards the direction away from the upper shell, the motor control unit includes a bus capacitor and a power module, the power module is electrically connected with the power distribution unit through the bus capacitor, the power module is arranged in the third installation cavity, and the bus capacitor is arranged in the fourth installation cavity.

[0012] According to some embodiments of the utility model, the lower shell is provided with a liquid cooling plate between the third installation cavity and the fourth installation cavity.

[0013] According to some embodiments of the utility model, a cooling flow channel is formed in the liquid cooling plate, the lower shell is further provided with a cooling liquid inlet and a cooling liquid outlet communicating with the cooling flow channel, a mounting opening communicating with the cooling flow channel is formed in the side of the liquid cooling plate towards the power module, and the power module is sealingly connected with the mounting opening.

[0014] The utility model discloses a second aspect proposes a kind of vehicles.

[0015] According to the vehicle of the second aspect embodiment of the utility model, it includes the above motor controller.

[0016] According to the vehicle of the second aspect of the utility model, through setting up distribution base and distribution connector, make motor controller provide voltage to motor control unit, meanwhile, provide voltage to external electric device, namely, motor controller integrates motor control and distribution box function, can promote the integration level of motor controller, save the occupied installation space. In addition, can reduce the installation difficulty of motor control unit and distribution unit, improve the assembly efficiency of motor controller.

[0017] Additional aspects and advantages of the utility model will be partially given in the following description, some will become obvious from the following description, or be understood through the practice of the utility model. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1 is the schematic diagram of motor controller according to the utility model embodiment;

[0019] Figure 2 is the schematic diagram of distribution unit and connecting copper bar and upper shell of motor controller according to the utility model embodiment;

[0020] Figure 3 is the schematic diagram of distribution base of motor controller according to the utility model embodiment;

[0021] Figure 4 is the schematic diagram of another angle of distribution base of motor controller according to the utility model embodiment;

[0022] Figure 5 is the circuit diagram of distribution base of motor controller according to the utility model embodiment;

[0023] Figure 6 is the schematic diagram of upper shell of motor controller according to the utility model embodiment;

[0024] Figure 7 is the schematic diagram of distribution connector of motor controller according to the utility model embodiment;

[0025] Figure 8 is the schematic diagram of control board assembly, connecting copper bar and upper shell of motor controller according to the utility model embodiment;

[0026] Figure 9 is the schematic diagram of fixed plate of motor controller according to the utility model embodiment;

[0027] Figure 10 is the schematic diagram of control board of motor controller according to the utility model embodiment;

[0028] Figure 11 is the schematic diagram of shielding plate of motor controller according to the utility model embodiment.

[0029] Figure 12 is a schematic view of a connecting copper bar of a motor controller according to an embodiment of the present application;

[0030] Figure 13 is a schematic view of a motor control unit and a lower shell of a motor controller according to an embodiment of the present application;

[0031] Figure 14 is a sectional view of Figure 13 ;

[0032] Figure 15 is a schematic view of a lower shell of a motor controller according to an embodiment of the present application;

[0033] Figure 16 is a schematic view of a bus capacitor of a motor controller according to an embodiment of the present application;

[0034] Figure 17 is a schematic view of a power module of a motor controller according to an embodiment of the present application;

[0035] Figure 18 is a schematic view of a drive board of a motor controller according to an embodiment of the present application.

[0036] Reference signs:

[0037] 100, motor controller;

[0038] 1, shell; 11, upper shell; 111, first window; 112, first mounting cavity; 113, second window; 114, third window; 115, fourth window; 116, fifth window; 117, sixth window; 118, first flange; 12, lower shell; 121, liquid cooling plate; 1211, cooling flow channel; 1212, mounting port; 122, cooling liquid inlet; 123, cooling liquid outlet; 124, seventh window; 125, second flange; 126, third mounting cavity; 127, fourth mounting cavity; 13, first cover plate; 14, second cover plate; 15, third cover plate; 16, fourth cover plate;

[0039] 2, motor control unit; 21, bus capacitor; 211, third positive copper bar; 2111, first connection point; 2112, second connection point; 212, third negative copper bar; 2121, third connection point; 2122, fourth connection point; 22, power module; 221, fourth positive copper bar; 222, fourth negative copper bar; 223, three-phase copper bar; 224, heat dissipation base; 225, drive terminal; 23, drive board; 231, third connector; 232, terminal via hole;

[0040] 3, power distribution unit; 31, power distribution base; 31a, fuse mounting position; 31b, first mounting point; 31c, second mounting point; 31d, third mounting point; 31e, fourth mounting point; 31f, fifth mounting point; 31g, sixth mounting point; 31h, seventh mounting point; 31i, eighth mounting point; 311, first positive copper bar; 312, first negative copper bar; 32, power distribution connector; 321, power distribution plug; 322, connection terminal; 33, filter;

[0041] 4, control board; 41, first connector; 42, second connector; 43, fifth mounting hole;

[0042] 5, fixed plate; 51, first avoiding opening; 52, second avoiding opening; 53, first mounting hole; 54, second mounting hole; 55, third mounting hole; 56, second mounting cavity;

[0043] 6, shielding plate; 61, third avoiding opening; 62, fourth mounting hole;

[0044] 7, connection copper bar; 71, second positive copper bar; 72, second negative copper bar. DETAILED DESCRIPTION

[0045] The embodiments of the present application will be described in detail below with reference to the drawings, wherein the same or similar components are denoted by the same reference numerals throughout the drawings. The embodiments described below with reference to the drawings are exemplary and are intended to explain the present application, and should not be understood as limiting the present application.

[0046] The following disclosure provides many different embodiments, or examples, for implementing different structures of the present application. For the purpose of simplification, the components and arrangements of the specific examples are described below. Of course, they are only examples and are not intended to limit the present application. In addition, the present application can repeatedly refer to the numbers and / or letters in different examples. Such repetition is for the purpose of simplification and clarity, and does not indicate the relationship between the various embodiments and / or arrangements discussed. In addition, the present application provides examples of various specific processes and materials, but those skilled in the art can realize the applicability of other processes and / or the use of other materials.

[0047] The motor controller 100 according to the first embodiment of the present application is described below with reference to the drawings.

[0048] As Figure 1 and Figure 2As shown, the motor controller 100 according to the first aspect of the present application comprises: a shell 1, a motor control unit 2 and a power distribution unit 3, the shell 1 comprises an upper shell 11 and a lower shell 12 which are independently formed and connected, the motor control unit 2 is arranged on the lower shell 12, the motor control unit 2 is adapted to be electrically connected with a motor and used for controlling the motor to work, the power distribution unit 3 is arranged on the upper shell 11, the power distribution unit 3 comprises a power distribution base 31 and a power distribution connector 32, the power distribution base 31 is adapted to be electrically connected with an external power supply device, the power distribution connector 32 is adapted to be electrically connected with an external power consumer, and the power distribution base 31 is electrically connected with the power distribution connector 32 and the motor control unit 2.

[0049] That is, the motor control unit 2 and the power distribution connector 32 can be electrically connected with the external power supply device through the power distribution base 31, that is, the voltage input by the external power supply device can be distributed and respectively delivered to the motor control unit 2 and the power distribution connector 32 through the power distribution base 31, since the motor control unit 2 is electrically connected with the motor, the external power consumer can be electrically connected with the motor controller 100 through the power distribution connector 32, so that the voltage distributed to the motor control unit 2 and the power distribution connector 32 can provide voltage for the motor control unit 2 and the external power consumer respectively. In other words, by arranging the power distribution base 31 and the power distribution connector 32, the motor controller 100 can provide voltage for the external power consumer while providing voltage for the motor control unit 2, that is, the motor controller 100 integrates the functions of motor control and power distribution box, and the installation space occupied by the separately arranged power distribution box is saved. Therefore, the integration level of the motor controller 100 can be improved to save the occupied installation space.

[0050] Moreover, during the assembly of the motor controller 100, the motor control unit 2 and the power distribution unit 3 can be respectively installed on the lower shell 12 and the upper shell 11, and then the upper shell 11 is connected with the lower shell 12. Therefore, compared with the controller layer-by-layer installation in the related art, the installation difficulty of the motor control unit 2 and the power distribution unit 3 can be reduced to improve the assembly efficiency of the motor controller 100.

[0051] According to the motor controller 100 of the first aspect of the present application, by arranging the power distribution base 31 and the power distribution connector 32, the motor controller 100 can provide voltage for the external power consumer while providing voltage for the motor control unit 2, that is, the motor controller 100 integrates the functions of motor control and power distribution box, and the integration level of the motor controller 100 can be improved to save the occupied installation space. In addition, the installation difficulty of the motor control unit 2 and the power distribution unit 3 can be reduced to improve the assembly efficiency of the motor controller 100.

[0052] According to some embodiments of the utility model, motor controller 100 still include with motor control unit 2 electric connection's control panel subassembly, upper shell 11 form with the first installation cavity 112 that opens to lower shell 12, distribution unit 3 is located in first installation cavity 112, control panel subassembly is located at the open mouth of first installation cavity 112, control panel subassembly is used to fix distribution unit 3 in first installation cavity 112. Among them, can send control instruction to motor control unit 2 through control panel subassembly to control the running state of motor. Therefore, control panel subassembly can consider the function of fixing distribution unit 3 on the basis of sending control instruction to motor control unit 2, so that the connecting piece needed for fixing distribution unit 3 can be saved, thereby the number of parts of motor controller 100 can be reduced, and the structure is compact.

[0053] According to some embodiments of the utility model, as shown in Figure 2 and Figure 6 Distribution base 31 includes first positive copper bar 311, first negative copper bar 312 and fuse, first positive copper bar 311 and first negative copper bar 312 are adapted to be electrically connected with the positive and negative of external power supply device respectively, first positive copper bar 311 is connected with the positive of motor control unit 2 and connected with the positive of distribution connector 32 through fuse, first negative copper bar 312 is connected with the negative of distribution connector 32 and motor control unit 2 simultaneously, first window 111 is formed on shell 1, and first window 111 is opposite to the fuse.

[0054] Among them, by setting fuse between first positive copper bar 311 and distribution connector 32, when the line is overloaded, the fuse can cut off the connection between first positive copper bar 311 and distribution connector 32, so as to play a good protection effect on the external power device connected with distribution connector 32. Therefore, by setting first window 111 on shell 1, when the fuse is damaged due to overload protection, the fuse can be replaced through first window 111, so as to reduce the difficulty of replacing the fuse.

[0055] According to some embodiments of the utility model, first window 111 is provided with first cover plate 13, and first cover plate 13 can open or close first window 111. Therefore, in the normal use process of motor controller 100, first window 111 can be closed through first cover plate 13 to improve the sealing performance of motor control box and ensure the reliability of motor control box, when the fuse needs to be replaced, first window 111 can be opened through the operation of first cover plate 13, so as to replace the fuse through first window 111. In other words, by setting first cover plate 13, the sealing performance of motor controller 100 can be ensured, and the replacement of fuse is facilitated. In one specific example, first cover plate 13 is fixed and detachable through screws.

[0056] In some embodiments, as shown in Figure 3 and Figure 4 The power distribution base 31 is formed with a fuse mounting position 31a for mounting a fuse, and the connection position of the power distribution connector 32 with the power distribution base 31 and the fuse mounting position 31a are located on opposite sides of the power distribution base 31. If the connection position of the power distribution connector 32 with the power distribution base 31 is located on the lower wall of the power distribution base 31, then the fuse mounting position 31a is located on the upper wall of the power distribution base 31. In this way, the connection position of the power distribution connector 32 with the power distribution base 31 and the fuse mounting position 31a can make full use of the space on opposite sides of the power distribution base 31, and the connection position of the power distribution connector 32 with the power distribution base 31 and the fuse mounting position 31a can be well spaced apart to prevent mutual obstruction and interference between the power distribution connector 32 and the fuse, facilitating the installation of the power distribution connector 32 and the fuse. In addition, the housing 1 is also formed with a second window 113, and the high-voltage wire harness of the external power supply device can extend into the housing 1 through the second window 113 and be connected with the power distribution base 31.

[0057] According to some embodiments of the present application, the control board assembly includes a control board 4, a fixing plate 5, and a shielding plate 6. The fixing plate 5 is fixed to the opening of the first mounting cavity 112 and is used to fix the power distribution unit 3 in the first mounting cavity 112. The shielding plate 6 is located on the side of the fixing plate 5 away from the power distribution unit 3, and the shielding plate 6 and the fixing plate 5 define a second mounting cavity 56 for mounting the control board 4. The second mounting cavity 56 defined by the fixing plate 5 and the shielding plate 6 together can provide good protection for the control board 4. At the same time, the shielding plate 6 can better shield external signals from interfering with the control board 4, thereby improving the stability and reliability of the control board 4.

[0058] In one specific example, the control board 4 is provided with a first connector 41 on the side facing the fixing plate 5, the first connector 41 is used for connecting with an external electric control device to realize signal transmission, the fixing plate 5 is formed with a second avoiding opening 52, the upper shell 11 is formed with a fourth window 115, the first connector 41 is arranged in the second avoiding opening 52 and extends out of the upper shell 11 through the fourth window 115, so as to facilitate the electric connection between the first connector 41 and the external electric control device, wherein the first connector 41 is in sealing cooperation with the second avoiding opening 52, so as to improve the sealing performance of the shell 1, the size of the second avoiding opening 52 is larger than the size of the fourth window 115, so as to reduce the difficulty of the first connector 41 passing through the second avoiding opening 52. The side of the control board 4 away from the fixing plate 5 is provided with a second connector 42, the second connector 42 is used for connecting with the drive board 23 of the motor control unit 2, the shielding plate 6 is formed with a third avoiding opening 61, the second connector 42 extends out of the second installation cavity 56 through the third avoiding opening 61. In addition, the fixing plate 5 is formed with a first installation hole 53, a second installation hole 54 and a third installation hole 55, the first installation hole 53 is used for connecting with the upper shell 11, the shielding plate 6 is formed with a fourth installation hole 62, the fourth installation hole 62 is arranged opposite to the second installation hole 54, the connection between the second installation hole 54 and the fourth installation hole 62 is realized by fastening the second installation hole 54 and the fourth installation hole 62 to the shielding plate 6, the control board 4 is formed with a fifth installation hole 43, the fifth installation hole 43 is arranged opposite to the third installation hole 55, the connection between the control board 4 and the fixing plate 5 is realized by fastening the third installation hole 55 and the fifth installation hole 43. Wherein, the first installation hole 53, the second installation hole 54, the third installation hole 55, the fourth installation hole 62 and the fifth installation hole 43 are all provided with a plurality of installation holes. And the fixing plate 5 has a cavity open to the shielding plate 6, a plurality of reinforcing ribs are formed in the cavity of the fixing plate 5 to improve the structural strength of the fixing plate 5.

[0059] According to some embodiments of the present application, the motor controller 100 further comprises a connecting copper bar 7, the power distribution unit 3 is electrically connected with the motor control unit 2 through the connecting copper bar 7, the control board assembly and the upper shell 11 define a first avoiding opening 51 in communication with the first installation cavity 112, one end of the connecting copper bar 7 connected with the power distribution unit 3 is located in the first installation cavity 112, the other end of the connecting copper bar 7 extends out of the first installation cavity 112 through the first avoiding opening 51. Therefore, through the cooperation of the control board assembly and the upper shell 11, the connection position of the connecting copper bar 7 and the power distribution unit 3 can be prevented from being exposed, so as to ensure the stability of the connection between the connecting copper bar 7 and the power distribution unit 3, the connecting copper bar 7 can extend out of the first installation cavity 112 through the first avoiding opening 51 to connect with the motor control unit 2, so as to reduce the connection difficulty between the connecting copper bar 7 and the motor control unit 2.

[0060] In some embodiments, the upper shell 11 is formed with a positioning column, and the connecting copper bar 7 is formed with a positioning hole, the positioning column and the positioning hole are inserted and matched to realize the installation and positioning of the connecting copper bar 7 on the upper shell 11. In addition, the upper shell 11 is further formed with a fifth window 116, and the fifth window 116 is arranged opposite to the end of the connecting copper bar 7 extending out of the first installation cavity 112, so that the connecting process of the connecting copper bar 7 and the motor control unit 2 can be carried out through the fifth window 116, and the maintenance is facilitated. In addition, the fifth window 116 is provided with a second cover plate 14 for opening or closing the fifth window 116, so as to ensure the sealing performance of the shell 1.

[0061] In some embodiments, the connecting copper bar 7 includes a second positive copper bar 71 and a second negative copper bar 72, and one end of the connecting copper bar 7 located in the first installation cavity 112 is connected with the output copper bar of the filter 33. In one specific example, the connecting copper bar 7 is independently formed. In another specific example, the connecting copper bar 7 is integrally formed with the output copper bar of the filter 33.

[0062] According to some embodiments of the present application, as shown in Figure 2 and Figure 7 The power distribution connector 32 includes a power distribution plug 321 and a plurality of connecting terminals 322 electrically connected with the power distribution plug 321, the connecting terminals 322 are electrically connected with the power distribution base 31, and the power distribution plug 321 extends to the outside of the shell 1. Therefore, the external power device can be connected with the connecting terminals 322 by being plugged with the power distribution plug 321 extending to the outside of the shell 1, so that the power distribution base 31 can supply power to the external power device through the connecting terminals 322 and the power distribution plug 321, and the connection difficulty of the external power device and the power distribution connector 32 can be reduced. In one specific example, the shell 1 is formed with a third window 114, the power distribution plug 321 is installed at the third window 114, and the connecting terminals 322 extend to the inside of the shell 1 through the third window 114.

[0063] In some embodiments, as shown in Figures 3 to 7As shown, the connection terminals 322 have four connection terminals 322 divided into two groups, each group having two connection terminals 322 for supplying power to one external electrical device, that is, the power distribution connector 32 can be electrically connected to two external electrical devices at the same time to supply power to the two external electrical devices at the same time. In addition, the power distribution base 31 is formed with a first mounting point 31b, a second mounting point 31c, a third mounting point 31d, a fourth mounting point 31e, a fifth mounting point 31f, a sixth mounting point 31g, a seventh mounting point 31h and an eighth mounting point 31i, specifically, the first positive copper bar 311 is directly connected to the first mounting point 31b, the second mounting point 31c and the third mounting point 31d at the same time, the first negative copper bar 312 is directly connected to the fourth mounting point 31e, the fifth mounting point 31f and the sixth mounting point 31g at the same time, the seventh mounting point 31h is directly connected to the eighth mounting point 31i, the positive line and the negative line of the external power supply device are connected to the first mounting point 31b and the fourth mounting point 31e respectively, the fuse is mounted on the second mounting point 31c and the seventh mounting point, that is, the second mounting point 31c is electrically connected to the seventh mounting point 31h through the fuse, the positive connection terminal 322 of the power distribution connector 32 is connected to the eighth mounting point 31i, the negative connection terminal 322 of the power distribution connector 32 is connected to the fifth mounting point 31f, and the third mounting point 31d and the sixth mounting point 31g are connected to the positive and negative poles of the motor control unit 2 respectively. Among them, the number of second mounting points 31c, fifth mounting points 31f, seventh mounting points 31h and eighth mounting points 31i is the same as the number of external electrical devices that can be connected to the power distribution connector 32 at the same time, for example, the power distribution connector 32 is connected to two external electrical devices such as the compressor of the vehicle air conditioning system and the electric heater at the same time, then the second mounting point 31c, the fifth mounting point 31f, the seventh mounting point 31h and the eighth mounting point 31i are each provided with two to correspond to the power supply to the two external electrical devices.

[0064] It should be noted that here is only an example of the number of external electrical devices that can be connected to the power distribution connector 32 at the same time in one case, and the number of external electrical devices that can be connected to the power distribution connector 32 at the same time can be flexibly adjusted according to actual use, which is not specifically limited here.

[0065] According to some embodiments of the present application, Figure 2 As shown, the power distribution unit 3 further comprises a filter 33, and the power distribution base 31 is electrically connected to the motor control unit 2 through the filter 33. That is, the voltage provided by the motor control unit 2 will pass through the filter 33 to select the frequency before entering the motor control unit 2, and the filter 33 can better filter out interference noise to suppress electromagnetic interference, so as to ensure more stable and efficient operation of the electrode.

[0066] In one specific example, the first window 111 is formed in the upper shell 11 and communicates with the first mounting cavity 112, and the upper shell 11 is further provided with a reinforcing rib on the side surface thereof facing the first mounting cavity 112, the reinforcing rib being located in the area where the filter 33 is mounted, so as to improve the protection effect on the filter 33.

[0067] In some embodiments, the upper shell 11 and the lower shell 12 are detachably connected. Therefore, during the assembly of the motor controller 100, the power distribution unit 3 is mounted on the upper shell 11, and the motor control unit 2 is mounted on the lower shell 12, and finally the upper shell 11 and the lower shell 12 are buckled and connected together, so that the assembly of the motor controller 100 can be realized, and the assembly difficulty of the motor controller 100 can be reduced. Moreover, when the power distribution unit 3 or the motor control unit 2 fails, only the connection relationship between the upper shell 11 and the lower shell 12 needs to be released, so that the failed part such as the failed power distribution unit 3 or the failed motor control unit 2 can be repaired separately, without the need to disassemble the normally functioning part, so that the difficulty of the later maintenance of the motor controller 100 can be reduced.

[0068] In one specific example, as shown in Figure 6 and Figure 15 the outer peripheral edge of the side of the upper shell 11 facing the lower shell 12 is formed with a first flange 118, and the outer peripheral edge of the side of the lower shell 12 facing the upper shell 11 is formed with a second flange 125, the first flange 118 and the second flange 125 are fitted and connected, so as to improve the connection stability of the upper shell 11 and the lower shell 12.

[0069] According to some embodiments of the present application, the lower shell 12 has a third mounting cavity 126 open toward the upper shell 11 and a fourth mounting cavity 127 open toward the direction away from the upper shell 11, the motor control unit 2 includes a bus capacitor 21 and a power module 22, the power module 22 is electrically connected to the power distribution unit 3 through the bus capacitor 21, the power module 22 is arranged in the third mounting cavity 126, and the bus capacitor 21 is arranged in the fourth mounting cavity 127. Therefore, during the installation of the motor control unit 2 to the lower shell 12, the power module 22 and the bus capacitor 21 can be respectively installed through the open mouths of the third mounting cavity 126 and the fourth mounting cavity 127, so as to reduce the mutual disturbance of the power module 22 and the bus capacitor 21 during the installation process, thereby reducing the assembly difficulty of the motor controller 100.

[0070] According to some embodiments of the present application, as shown in Figure 13 and Figure 14As shown, the lower shell 12 is provided with a liquid cooling plate 121 between the third mounting cavity 126 and the fourth mounting cavity 127. That is, the liquid cooling plate 121 is located between the bus capacitor 21 and the power module 22. Therefore, the distance between the bus capacitor 21 and the liquid cooling plate 121 can be shortened, and the uniformity of the cooling effect of the liquid cooling plate 121 on the bus capacitor 21 and the power module 22 can be improved.

[0071] According to some embodiments of the present utility model, as Figure 14 and 15 As shown, the liquid cooling plate 121 is formed with a cooling flow channel 1211, and the lower shell 12 is further formed with a cooling liquid inlet 122 and a cooling liquid outlet 123 in communication with the cooling flow channel 1211. The side of the liquid cooling plate 121 facing the power module 22 is formed with a mounting port 1212 in communication with the cooling flow channel 1211, and the power module 22 is sealingly connected with the mounting port 1212. That is, the cooling liquid can enter the cooling flow channel 1211 through the cooling liquid inlet 122, contact and exchange heat with the part of the power module 22 sealingly connected with the mounting port 1212, and then be discharged through the cooling liquid outlet 123, so as to cool the power module 22. Therefore, by arranging the mounting port 1212, the power module 22 can be more directly contacted with the cooling liquid, so as to improve the cooling effect on the power module 22.

[0072] In some embodiments, as Figures 16 to 18 As shown, the bus capacitor 21 includes a third positive copper bar 211 and a third negative copper bar 212, and the power module 22 includes a fourth positive copper bar 221, a fourth negative copper bar 222, a three-phase copper bar 223, a heat dissipation base 224, and a driving terminal 225. The third positive copper bar 211 is provided with a first connecting point 2111 and a second connecting point 2112, and the third negative copper bar 212 is provided with a third connecting point 2121 and a fourth connecting point 2122. The first connecting point 2111 and the third connecting point 2121 are respectively connected with the second positive copper bar 71 and the second negative copper bar 72 of the connecting copper bar 7, the second connecting point 2112 and the fourth connecting point 2122 are respectively connected with the fourth positive copper bar 221 and the fourth negative copper bar 222, and the three-phase copper bar 223 is connected with the motor.

[0073] The heat dissipation base 224 is sealingly connected with the mounting port 1212, and the side of the heat dissipation base 224 facing the cooling flow channel 1211 is formed with a fin structure. The distance between the fin structure and the inner wall surface of the cooling flow channel 1211 is greater than 0 and not greater than 0.5 mm, so that the cooling liquid can better contact and exchange heat with the fin structure. The distance between the fin structure and the inner wall surface of the cooling flow channel 1211 can be 0.05 mm, 0.1 mm, 0.15 mm, 0.2 mm, 0.25 mm, 0.3 mm, 0.35 mm, 0.4 mm, 0.45 mm, 0.5 mm, etc.

[0074] The power module 22 is provided with a drive board 23 on the side away from the bus capacitor 21, the drive board 23 is provided with a third connector 231 on the side away from the power module 22, the third connector 231 is plugged with the second connector 42, a plurality of terminal through holes 232 are formed on the drive board 23, and the drive terminals 225 on the power module 22 are arranged in the terminal through holes 232 and welded with the drive board 23.

[0075] The third mounting cavity 126 and the fourth mounting cavity 127 are formed in the lower shell 12, the third mounting cavity 126 and the fourth mounting cavity 127 are located on opposite sides of the liquid cooling plate 121, the third mounting cavity 126 is open toward the upper shell 11, the fourth mounting cavity 127 is open away from the upper shell 11, the power module 22 and the drive board 23 are arranged in the third mounting cavity 126, and the bus capacitor 21 is arranged in the fourth mounting cavity 127, the fourth mounting cavity 127 is provided with a third cover plate 15 for opening or closing the opening, so as to facilitate the installation and maintenance of the bus capacitor 21. In addition, the upper shell 11 is further provided with a sixth window 117 opposite to the three-phase copper bar 223, and the lower shell 12 is further provided with a seventh window 124 opposite to the three-phase copper bar 223, the connecting line of the motor is connected with the three-phase copper bar 223 through the seventh window 124, and the operator can connect the three-phase copper bar 223 with the motor through the sixth window 117, and the sixth window 117 is provided with a fourth cover plate 16 for opening or closing the sixth window 117, so as to ensure the sealing performance of the shell 1.

[0076] In a specific example, the power module 22 and the drive board 23 are both provided with two, the two power modules 22 are electrically connected with the power distribution unit 3 through the bus capacitor 21, the two power modules 22 are respectively connected with two motors, and the control board 4 is provided with two second connectors 42, so as to control the two motors. That is, the motor controller 100 can realize double motor control.

[0077] A vehicle according to the second aspect of the present application will be described below with reference to the drawings.

[0078] The vehicle according to the second aspect of the present application comprises a motor controller 100.

[0079] According to the vehicle of the second aspect of the present application, the power distribution base 31 and the power distribution connector 32 are arranged, so that the motor controller 100 provides voltage to the motor control unit 2 and also provides voltage to the external power device, that is, the motor controller 100 integrates the functions of the motor control and the power distribution box, so as to improve the integration level of the motor controller 100 and save the occupied installation space. In addition, the installation difficulty of the motor control unit 2 and the power distribution unit 3 can be reduced, so as to improve the assembly efficiency of the motor controller 100.

[0080] In the present application, unless otherwise explicitly specified and limited, the terms "mounting", "connecting", "connecting", "fixing" and the like should be understood in a broad sense, for example, it can be fixedly connected, or it can be detachably connected, or it can be integrated; it can be directly connected, or it can be indirectly connected through an intermediate medium; it can be the internal communication of two elements or the interaction relationship of two elements. For ordinary skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0081] In the description of the present application, the description of the terms "one embodiment", "some embodiments", "example", "specific example" or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. In the present application, the illustrative description of the above terms is not necessarily for the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art can combine and combine the different embodiments or examples described in the present application and the features of the different embodiments or examples without contradiction.

[0082] Although the embodiments of the present application have been shown and described, those skilled in the art can understand that various changes, modifications, replacements and variations can be made to these embodiments without departing from the principles and purposes of the present application, and the scope of the present application is defined by the claims and their equivalents.

Claims

1. An electric motor controller characterized by, The motor controller comprises: a housing comprising an upper housing and a lower housing which are separately formed and connected; a motor control unit arranged in the lower housing, the motor control unit being adapted to be electrically connected with a motor and used for controlling the operation of the motor; a power distribution unit arranged in the upper housing, the power distribution unit comprising a power distribution base and a power distribution connector, the power distribution base being adapted to be electrically connected with an external power supply, the power distribution connector being adapted to be electrically connected with an external electrical device, and the power distribution base being electrically connected with the power distribution connector and the motor control unit.

2. The motor controller of claim 1, wherein, The motor controller further comprises a control board assembly electrically connected with the motor control unit, the upper housing is formed with a first installation cavity which is open towards the lower housing, the power distribution unit is arranged in the first installation cavity, and the control board assembly is arranged at the opening of the first installation cavity and used for fixing the power distribution unit in the first installation cavity.

3. The motor controller of claim 2, wherein, The control board assembly comprises a control board, a fixing plate and a shielding plate, the fixing plate is fixedly arranged at the opening of the first installation cavity and used for fixing the power distribution unit in the first installation cavity, and the shielding plate is arranged on the side of the fixing plate which is away from the power distribution unit and defines a second installation cavity with the fixing plate for installing the control board.

4. The motor controller of claim 2, wherein, The motor controller further comprises a connecting copper bar, the power distribution unit is electrically connected with the motor control unit through the connecting copper bar, and a first avoiding opening which is in communication with the first installation cavity is defined between the control board assembly and the upper housing, one end of the connecting copper bar which is connected with the power distribution unit is arranged in the first installation cavity, and the other end of the connecting copper bar extends out of the first installation cavity through the first avoiding opening.

5. The motor controller of claim 1, wherein, The power distribution connector comprises a power distribution plug and a plurality of connecting terminals which are electrically connected with the power distribution plug, the connecting terminals are electrically connected with the power distribution base, and the power distribution plug extends out of the housing.

6. The motor controller of claim 1, wherein, The power distribution unit further comprises a filter, and the power distribution base is electrically connected with the motor control unit through the filter.

7. The motor controller of claim 1, wherein, The lower housing is provided with a third installation cavity which is open towards the upper housing and a fourth installation cavity which is open away from the upper housing, the motor control unit comprises a bus capacitor and a power module, the power module is electrically connected with the power distribution unit through the bus capacitor, the power module is arranged in the third installation cavity, and the bus capacitor is arranged in the fourth installation cavity.

8. The motor controller of claim 7, wherein, The lower housing is provided with a liquid cooling plate which is arranged between the third installation cavity and the fourth installation cavity.

9. The motor controller of claim 8, wherein, The liquid cooling plate is formed with a cooling flow channel, the lower housing is further formed with a cooling liquid inlet and a cooling liquid outlet which are in communication with the cooling flow channel, the side of the liquid cooling plate which faces the power module is formed with a mounting opening which is in communication with the cooling flow channel, and the power module is sealingly connected with the mounting opening.

10. A vehicle characterized by comprising: The motor controller according to any one of claims 1-9. ​

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