Integrated controller and vehicle

Abstract

The utility model discloses an integrated controller and a vehicle. Relates to the technical field of vehicle control. The problem that the integration level of a controller is low is at least solved. The utility model provides an integrated controller. The integrated controller comprises a shell, a driving control module and an electric control module, wherein the driving control module and the electric control module are arranged in the shell. The driving control module and the electric control module are arranged in the shell, compared with a plurality of controllers which are arranged in a scattered mode, the occupied space in the vehicle is reduced, and the integration of the controller is improved. Therefore, only one integrated unit needs to be detected, and a plurality of dispersed controllers do not need to be found at different parts of the vehicle, so that the maintenance steps are simplified, and the maintenance efficiency is improved.

Description

TECHNICAL FIELD

[0001] The utility model relates to vehicle control technical field especially relates to an integrated controller and vehicle. BACKGROUND

[0002] The vehicle control system is a complex and key system, and is used for guaranteeing stable and efficient operation of the vehicle, and covers power transmission, driving control and realization of various functions.

[0003] In the prior art, the electric vehicle is powered by a battery, and a high-voltage power distribution module is used to distribute power to various power-consuming devices, so as to guarantee normal driving of the vehicle and driving experience. The power distribution process needs to pass through corresponding current hall, contactor, fuse, controller and corresponding electric control setting. A large number of high-voltage cables, high-voltage connectors, low-voltage cables, low-voltage connectors, cooling pipelines and fixing supports and other connecting components are needed between these devices.

[0004] In the prior art, the integration level of the controller is low. UTILITY MODEL CONTENTS

[0005] The embodiment of the utility model provides an integrated controller and vehicle to at least solve the problem of low integration level of the controller.

[0006] In the first aspect, the application provides an integrated controller for a vehicle. The integrated controller includes a housing, a drive control module and an electric control module arranged in the housing.

[0007] By arranging the drive control module and the electric control module in the housing, compared with multiple controllers arranged in dispersion, the space occupied in the vehicle is reduced, and the integration of the controller is improved. In this way, only one integrated unit needs to be detected, and multiple dispersed controllers do not need to be searched in different parts of the vehicle, thereby simplifying the maintenance steps and improving the maintenance efficiency.

[0008] In a possible implementation, the housing includes a partition and a side frame arranged around the partition. The partition separates the space in the side frame into a first accommodating cavity and a second accommodating cavity. The drive control module is arranged in the first accommodating cavity. The electric control module is arranged in the second accommodating cavity.

[0009] In a possible implementation, the drive control module includes a power component and a capacitor component. The capacitor component is connected with the power component, and the capacitor component and the power component are arranged along the arrangement direction of the first accommodating cavity and the second accommodating cavity.

[0010] In a possible implementation, the drive control module includes an electromagnetic isolation component arranged between the power component and the capacitor component.

[0011] In a possible implementation, the electromagnetic isolation part is provided with a cooling space. The integrated controller comprises a cooling channel. The cooling channel is used for heat dissipation of the drive control module and the electric control module. The cooling space forms part of the cooling channel.

[0012] In a possible implementation, the partition part is provided with a cooling flow path, the cooling flow path is in communication with the cooling space, and the cooling flow path forms part of the cooling channel.

[0013] In a possible implementation, the power part is located between the partition part and the capacitor part; at least part of the power part is arranged opposite at least part of the cooling flow path along the arrangement direction of the first accommodating cavity and the second accommodating cavity. Alternatively, the capacitor part is located between the power part and the partition part; at least part of the capacitor part is arranged opposite at least part of the cooling flow path along the arrangement direction of the first accommodating cavity and the second accommodating cavity.

[0014] In a possible implementation, the electric control module comprises a low-voltage control module. The low-voltage control module is used for adjusting voltage to output direct current voltages of different sizes, and the low-voltage control module is arranged in the second accommodating cavity.

[0015] In a possible implementation, the integrated controller comprises a cooling channel. The partition part is provided with a cooling flow path, and the cooling flow path forms at least part of the cooling channel. At least part of the low-voltage control module is arranged opposite at least part of the cooling flow path along the arrangement direction of the first accommodating cavity and the second accommodating cavity.

[0016] In a possible implementation, the electric control module comprises a steering control module. The steering control module is arranged in the second accommodating cavity.

[0017] In a possible implementation, the electric control module comprises a safety control module. The safety control module is used for charging and discharging compressed air, and the safety control module is arranged in the second accommodating cavity.

[0018] In a possible implementation, at least part of the steering control module and / or at least part of the safety control module is arranged opposite at least part of the cooling flow path along the arrangement direction of the first accommodating cavity and the second accommodating cavity.

[0019] In a possible implementation, the shell further comprises a second electromagnetic isolation part. The second electromagnetic isolation part is located in the second accommodating cavity and connected with the partition part. The second electromagnetic isolation part is arranged between the steering control module and the low-voltage control module, and the second electromagnetic isolation part is arranged between the safety control module and the low-voltage control module.

[0020] In a possible implementation, the integrated controller further comprises an inductor arranged in the first accommodating cavity. The shell further comprises a third electromagnetic isolation member arranged in the first accommodating cavity and connected with the partition, and the third electromagnetic isolation member is arranged between the inductor and the drive control module.

[0021] In a possible implementation, the integrated controller further comprises a DC filter. The DC filter is arranged in the first accommodating cavity. The shell further comprises a fourth electromagnetic isolation member arranged in the first accommodating cavity and connected with the partition, and the fourth electromagnetic isolation member is arranged between the drive control module and the DC filter.

[0022] In a possible implementation, the drive control module further comprises a contactor arranged in the first accommodating cavity. The shell further comprises a fifth electromagnetic isolation member arranged in the first accommodating cavity and connected with the partition, and the fifth electromagnetic isolation member is arranged between the contactor and the DC filter.

[0023] In a possible implementation, the integrated controller further comprises a current sampling assembly arranged in the second accommodating cavity, and the current sampling assembly is connected with the drive control module and the electronic control module respectively, and the current sampling assembly is configured to sample current in the drive control module and the electronic control module.

[0024] In a possible implementation, the integrated controller further comprises a fuse assembly. The fuse assembly is connected with the drive control module and the electronic control module. The periphery of the side frame is further provided with a third accommodating cavity, and an opening is formed at one end of the third accommodating cavity opposite to the side frame. The fuse assembly is arranged in the third accommodating cavity.

[0025] In a second aspect, the present application provides a vehicle comprising the integrated controller according to any one of the possible implementation examples of the first aspect. BRIEF DESCRIPTION OF DRAWINGS

[0026] Figure 1 An exploded schematic view of an integrated controller according to an embodiment of the present application;

[0027] Figure 2 An exploded schematic view of an integrated controller according to an embodiment of the present application;

[0028] Figure 3 A high-voltage power distribution topology according to an embodiment of the present application;

[0029] Figure 4 A structural schematic view of a first accommodating cavity according to an embodiment of the present application;

[0030] Figure 5 A structural schematic view of a second accommodating cavity according to an embodiment of the present application;

[0031] Figure 6 A structural schematic diagram of a drive control module provided by an embodiment of the present application;

[0032] Figure 7A A structural schematic diagram of a capacitor and a power provided by the prior art;

[0033] Figure 7B A structural schematic diagram of a capacitor and a power provided by the prior art; Figure 7A A sectional view along A-A direction in the capacitor and the power provided by the prior art;

[0034] Figure 8 A structural schematic diagram of a current sampling assembly provided by an embodiment of the present application.

[0035] Reference signs:

[0036] 0100-integrated controller;

[0037] 1-housing; 0101-separation part; 0102-side frame; 0103-first accommodating cavity; 0104-second accommodating cavity; 0105-third accommodating cavity; 0106-cooling flow path; 1001-right water inlet; 1002-right solid water channel A area; 1003-right solid water channel B area; 1004-right solid water channel C area; 1005-air compression steering cooling water channel; 1006-right solid water channel D area; 1007-secondary filtering cooling water channel; 1008-right water outlet; 1009-left water inlet; 1010-left solid water channel A area; 1011-left solid water channel B area; 1012-left solid water channel C area; 1013-DC cooling water channel; 1014-left solid water channel D area; 1015-left water outlet;

[0038] 1016 - left drive board connects main control board wire harness via hole; 1017 - control board connects contactor & hall assembly wire harness via hole; 1018 - main drive contactor busbar pre-charging high voltage wire harness via hole; 1019 - right drive board connects main control board wire harness via hole; 1020 - left drive three-phase connector via hole; 1021 - right drive three-phase connector via hole; 1022 - upper connector via hole; 1023 - fuse seat installation cavity; 1024 - fuse copper bar via hole; 1025 - DCM (defrosting power distribution) connector via hole; 1026 - PTC1 (battery water cooling / heating) connector via hole; 1027 - PTC2 (electric heating) connector via hole; 1028 - DC input copper bar fixing seat installation cavity; 1029 - DC busbar connector via hole; 1030 - ACM (air compressor) connector via hole; 1031 - EHPS (steering) connector via hole; 1032 - DC output connector via hole; 1033 - first air conditioner connector via hole; 1034 - second air conditioner connector via hole; 1035 - upper box left drive air valve protection wall; 1036 - upper box right drive air valve protection wall; 1037 - lower box left drive air valve protection wall; 1038 - lower box right drive air valve protection wall; 1039 - third electromagnetic isolation; 1040 - fuse isolation wall; 1041 - fourth electromagnetic isolation; 1042 - fifth electromagnetic isolation; 1043 - air conditioner magnetic ring isolation wall; 1044 - second electromagnetic isolation; 1045 - air compressor steering assembly and right drive board connects main control board wire harness isolation wall;

[0039] 0200 - cooling channel; 0201 - first electromagnetic isolation;

[0040] 2 - electric control box left waterway cover plate; 2001 - left drive IGBT waterway inlet; 2002 - left drive IGBT waterway; 2003 - left drive IGBT sealing groove; 2004 - left drive IGBT waterway outlet; 3 - electric control box right waterway cover plate; 3001 - right drive IGBT waterway inlet; 3002 - right drive IGBT waterway; 3003 - right drive IGBT sealing groove; 3004 - right drive IGBT waterway outlet;

[0041] 0300 - drive control module; 0301 - power component; 0302 - capacitor component;

[0042] 0400 - electric control module; 0401 - low-voltage control module; 0402 - steering control module; 0403 - safety control module;

[0043] 4 - left drive IGBT assembly; 4001 - left drive IGBT three-phase output copper bar; 4002 - left drive IGBT negative input copper bar; 4003 - left drive IGBT positive input copper bar; 5 - left drive capacitor and IGBT positive connection copper bar; 6 - left drive capacitor and IGBT connection positive and negative copper bar insulation baffle; 7 - left drive capacitor and IGBT negative connection copper bar; 8 - left drive capacitor assembly; 8001 - left drive capacitor positive output copper bar; 8002 - left drive capacitor negative output copper bar; 8003 - left drive capacitor positive input copper bar; 8004 - left drive capacitor negative input copper bar; 8005 - left drive capacitor positive and negative output copper bar isolation rib; 8006 - left drive capacitor positive and negative input copper bar isolation rib; 8007 - left drive capacitor negative sampling terminal; 8008 - left drive capacitor positive sampling terminal; 9 - electric control upper cover; 10 - left drive three-phase magnetic ring; 11 - right drive three-phase magnetic ring; 12 - left drive Hall assembly; 13 - right drive Hall assembly; 14 - left drive board; 15 - right drive board; 16 - left drive board connection main control board wiring harness; 17 - right drive board connection main control board wiring harness; 18 - left drive relief plate; 19 - right drive relief plate; 20 - left drive three-phase connector; 21 - right drive three-phase connector; 22 - left drive W-phase copper bar; 23 - left drive V-phase copper bar; 24 - left drive U-phase copper bar; 25 - right drive U-phase copper bar; 26 - right drive V-phase copper bar; 27 - right drive W-phase copper bar; 28 - right drive IGBT assembly; 29 - right drive capacitor and IGBT positive connection copper bar; 30 - right drive capacitor and IGBT connection positive and negative copper bar insulation baffle; 31 - right drive capacitor and IGBT negative connection copper bar; 32 - right drive capacitor assembly;

[0044] 33 - left drive waterway cover inlet sealing ring; 34 - left drive waterway cover outlet sealing ring; 35 - right drive waterway cover inlet sealing ring; 36 - right drive waterway cover outlet sealing ring; 37 - main drive capacitor input positive copper bar assembly; 38 - DC input negative copper bar; 39 - inductor; 40 - main drive insurance assembly; 41 - first main drive insurance input copper bar; 42 - second main drive insurance input copper bar; 43 - high-voltage Hall plate; 44 - main control board No. 1 main drive contactor bus pre-charged high-voltage wiring harness; 45 - main control board No. 2 main drive contactor bus pre-charged high-voltage wiring harness; 46 - upper installation connector; 47 - upper installation insurance output copper bar; 48 - upper installation connector negative connection copper bar; 49 - upper installation insurance input copper bar; 50 - main control board auxiliary contactor bus pre-charged high-voltage wiring harness;

[0045] 0500 - contactor;

[0046] 51 - first main drive contactor; 52 - second main drive contactor; 53 - auxiliary contactor; 54 - DC contactor; 55 - DC negative copper bar assembly; 56 - DC negative copper column fixing seat; 57 - DC input positive copper bar; 58 - DC contactor output copper bar; 59 - DC bus pre-charge resistor high-voltage wire harness; 60 - main control board DC contactor bus pre-charge high-voltage wire harness;

[0047] 61 - DC filter;

[0048] 62 - DC input copper bar fixing seat; 6201 - DC input positive copper bar; 6202 - DC input negative copper bar; 63 - air vent valve; 64 - left water inlet pipe; 65 - left water outlet pipe; 66 - right water inlet pipe; 67 - right water outlet pipe; 68 - shock absorbing pad; 69 - DC assembly; 70 - DC shield cover; 71 - DC output connection control board low-voltage power supply wire harness; 72 - control board connection DC assembly wire harness; 73 - air compressor IGBT; 74 - steering IGBT; 75 - air compressor steering drive board; 76 - Hall board connection main control board wire harness; 77 - air compressor high-voltage positive wire harness; 78 - steering high-voltage positive wire harness; 79 - air compressor high-voltage negative wire harness; 80 - steering high-voltage negative wire harness; 81 - air compressor motor three-phase wire harness; 82 - air compressor magnetic ring; 83 - steering magnetic ring; 84 - control board support shield plate; 85 - control board; 86 - steering motor three-phase wire harness; 87 - air compressor steering magnetic ring fixing seat; 88 - air compressor connector; 89 - steering connector; 90 - upper shield cover of adapter plate; 91 - low-voltage connector adapter plate; 92 - low-voltage connector shield cover; 93 - low-voltage connector; 94 - first air conditioner connector; 95 - second air conditioner connector; 96 - upper connector mounting hole cover plate; 97 - air conditioner connector magnetic ring fixing seat; 98 - first air conditioner magnetic ring; 99 - second air conditioner magnetic ring; 101 - first air conditioner power distribution negative wire harness; 102 - first air conditioner power distribution positive wire harness; 103 - second air conditioner power distribution negative wire harness; 104 - second air conditioner power distribution positive wire harness;

[0049] 0600 - current sampling assembly;

[0050] 105 - DC line fuse and Hall board connection copper bar assembly; 10501 - Hall board; 10502 - total adapter copper bar; 10503 - first air conditioner power distribution adapter copper bar; 10504 - second air conditioner power distribution adapter copper bar; 10505 - DC high-voltage adapter copper bar; 10506 - steering high-voltage adapter copper bar; 10507 - air compressor high-voltage adapter copper bar; 10508 - defrosting power distribution adapter copper bar; 10509 - PTC2 power distribution adapter copper bar; 10510 - PTC1 power distribution adapter copper bar; 106 - DC high-voltage positive wire harness; 107 - DC high-voltage negative wire harness; 108 - fuse fixing seat; 109 - upper fuse; 110 - pre-charge resistor; 111 - pre-charge group connection main control board high-voltage wire harness;

[0051] 0700 - insurance components;

[0052] 112 - first air conditioner insurance; 113 - second air conditioner insurance; 114 - DC insurance; 115 - steering insurance; 116 - air compressor insurance; 117 - defrosting insurance; 118 - second PTC insurance; 119 - first PTC insurance; 120 - defrosting power distribution negative pole wire harness; 121 - second PTC power distribution negative pole wire harness; 122 - first PTC power distribution negative pole wire harness; 123 - defrosting power distribution positive pole wire harness; 124 - second PTC power distribution positive pole wire harness; 125 - first PTC power distribution positive pole wire harness; 126 - main control board high-voltage bus negative pole wire harness; 127 - PTC and defrosting plug-in magnetic ring fixing seat; 128 - DCM (defrosting) power distribution plug-in; 129 - second PTC (electric heating) power distribution plug-in; 130 - first PTC (battery water cooling / heating) power distribution plug-in; 131 - DC bus; 132 - insurance side cover; 133 - DC bus side cover; 134 - electric control lower cover; 135 - control board connection contactor and Hall assembly wire harness. DETAILED DESCRIPTION

[0053] The embodiments of the present application will be described in detail below with reference to the drawings.

[0054] In the description of the present application, it is to be understood that the terms "upper", "lower", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and therefore cannot be understood as indicating or implying that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application.

[0055] The terms "first", "second", "third", "fourth", "fifth" are only for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the technical features indicated. Therefore, the features defined with "first", "second", "third", "fourth", "fifth" can explicitly or implicitly include one or more of the features. In the description of the present application, unless otherwise specified, the meaning of "a plurality of" is two or more.

[0056] In the description of the utility model, it is necessary to explain that, unless there is definite stipulation and limitation, the term "installation", "connection" should be understood broadly, for example, it can be fixed connection, also can be detachable connection, or integrally connected, it can be mechanical connection, also can be electrical connection, it can be direct connection, also can be indirect connection through intermediate medium, it can be the communication inside two elements, for ordinary skilled in the art, the specific meaning of the above-mentioned term in the utility model can be understood according to specific circumstances.In addition, when describing pipeline or channel, "connection" used in the application has the meaning of conducting.In the specific meaning, it needs to be understood in combination with context.

[0057] In the embodiments of the present application, the words such as "exemplary" or "for example" are used to mean serving as an example, instance, or illustration. Any embodiment or design presented as "exemplary" or "for example" in the embodiments of the present application should not be construed as being more preferred or advantageous than other embodiments or design solutions. In fact, the use of the words such as "exemplary" or "for example" is intended to present related concepts in a specific manner.

[0058] As used herein, "about", "approximately", or "around" includes the recited value and the average value within an acceptable deviation range of the specific value, wherein the acceptable deviation range is determined by the ordinary skilled in the art considering the measurement being discussed and the error related to the measurement of the specific quantity (i.e., the limitation of the measurement system).

[0059] Referring to Figure 1 and Figure 2 As shown in the drawings, the present application provides an integrated controller 0100 for a vehicle. The integrated controller 0100 comprises a housing 1, a drive control module 0300 and an electronic control module 0400 arranged in the housing 1.

[0060] By arranging the drive control module 0300 and the electronic control module 0400 in the housing 1, compared with multiple controllers arranged in dispersion, the space occupied in the vehicle is reduced, and the integration of the controller is improved.

[0061] In this way, only one integrated unit needs to be detected, and multiple dispersed controllers in different parts of the vehicle do not need to be found, thereby simplifying the maintenance steps and improving the maintenance efficiency.

[0062] Further, one integrated controller 0100 replaces multiple dispersed controllers, reduces the number of housings, circuits and other hardware, and reduces the hardware procurement and production cost.

[0063] Meanwhile, the integrated controller 0100 shortens the signal transmission distance between the drive control module 0300 and the electronic control module 0400, reduces the length of the signal transmission line, reduces the possibility of signal interference, improves signal transmission speed and stability, and reduces signal delay or distortion.

[0064] The embodiments of this application are described in detail below with reference to the accompanying drawings, and the application scenarios of the embodiments of this application are first introduced before the detailed description of the embodiments of this application.

[0065] The integrated controller 0100 provided in this application can be used in vehicles.

[0066] This application provides a vehicle, which includes an integrated controller 0100. The vehicle can be an electric vehicle, a hybrid vehicle powered by electric energy or other energy sources. Furthermore, the vehicle can be a sedan, SUV, MPV, sports car, racing car, truck, bus, engineering vehicle, special vehicle, etc.

[0067] like Figure 3 As shown in the diagram, the high-voltage power distribution topology of a vehicle mainly includes three parts: battery, PDU (Power Distribution Unit), and electric powertrain. Current enters the control section of the electric powertrain, passes through corresponding current Hall effect sensors, contactors, fuses, and controllers, and then flows out from various connectors around the enclosure.

[0068] See Figure 4 and Figure 5 and combined Figure 1 and Figure 2 As shown, in one possible embodiment, the housing 1 includes a partition 0101 and a side frame 0102 surrounding the partition 0101. The partition 0101 divides the space within the side frame 0102 into a first accommodating cavity 0103 and a second accommodating cavity 0104. A drive control module 0300 is disposed in the first accommodating cavity 0103. An electronic control module 0400 is disposed in the second accommodating cavity 0104.

[0069] The drive control module 0300 generates strong electromagnetic signals during operation, while the electronic control module 0400 has high requirements for the electromagnetic environment. The partition 0101 confines the electromagnetic interference generated by the drive control module 0300 within the first accommodating cavity 0103, reducing its propagation to the second accommodating cavity 0104 where the electronic control module 0400 is located, thereby improving the stability and accuracy of the electronic control system.

[0070] In one possible implementation, the housing 1 has multiple through holes for wiring, routing, and device installation.

[0071] See Figure 6 and combined Figure 1 and Figure 2As shown in FIG. 1, in one possible implementation, the drive control module 0300 includes a power component 0301 and a capacitor component 0302. The capacitor component 0302 is connected to the power component 0301, and the capacitor component 0302 and the power component 0301 are arranged along the arrangement direction of the first accommodating cavity 0103 and the second accommodating cavity 0104.

[0072] It should be noted that the power component 0301 and the capacitor component 0302 are two parts with relatively large volumes in the drive control module 0300, and thus the power component 0301 and the capacitor component 0302 are main parts affecting the volume of the drive control module 0300.

[0073] Referring to Figure 7A and Figure 7B , in the prior art, the power component 0301 and the capacitor component 0302 are arranged along the horizontal direction, which occupies a large space in the horizontal direction.

[0074] Referring to Figure 6 , and referring to Figure 1 and Figure 2 , arranging the capacitor component 0302 and the power component 0301 along the arrangement direction of the first accommodating cavity 0103 and the second accommodating cavity 0104 can better adapt to the space structure inside the shell 1. The space occupation in the direction perpendicular to the arrangement direction of the first accommodating cavity 0103 and the second accommodating cavity 0104 is reduced, and more space is left for other components installed in this direction.

[0075] Further, arranging the capacitor component 0302 and the power component 0301 along the arrangement direction of the first accommodating cavity 0103 and the second accommodating cavity 0104 makes them have clear installation positions and sequences during assembly, which facilitates the operation of workers.

[0076] In summary, arranging the capacitor component 0302 and the power component 0301 along the arrangement direction of the first accommodating cavity 0103 and the second accommodating cavity 0104 can make the overall layout of the drive control module 0300 more compact, and thus facilitate the integration of more modules.

[0077] In one possible implementation, the arrangement direction of the first accommodating cavity 0103 and the second accommodating cavity 0104 is a direction perpendicular to the horizontal direction. When the shell 1 is installed in a vehicle, the openings of the first accommodating cavity 0103 and the second accommodating cavity 0104 face the direction parallel to the horizontal plane.

[0078] Referring to Figure 1 and Figure 2 , in one possible implementation, the drive control module 0300 includes a first electromagnetic isolation component 0201, which is arranged between the power component 0301 and the capacitor component 0302.

[0079] The first electromagnetic isolation member 0201 can reduce the radiation interference and electromagnetic interference between the power member 0301 and the capacitor member 0302, so that the capacitor member 0302 can work in a relatively stable electromagnetic environment, and thus the speed of performance degradation of the capacitor can be reduced.

[0080] In an example, the capacitor member 0302 includes a left drive capacitor assembly 8 and a right drive capacitor assembly 32.

[0081] In an example, the power member 0301 includes a left drive IGBT assembly 4 and a right drive IGBT assembly 28.

[0082] Continuing to refer to Figure 1 and Figure 2 , in a possible implementation, a cooling space is arranged in the electromagnetic isolation member. The integrated controller 0100 includes a cooling channel 0200. The cooling channel 0200 is used to dissipate heat of the drive control module 0300 and the electric control module 0400. The cooling space forms part of the cooling channel 0200.

[0083] When the drive control module 0300 is running, the power member 0301 and the capacitor member 0302 can generate heat.

[0084] The cooling space, as part of the cooling channel 0200, increases the contact area and heat dissipation path of the cooling channel 0200 and the heat generating elements. When the cooling medium flows in the cooling space, it can more fully absorb the heat generated by the electromagnetic isolation member and the power member 0301 and the capacitor member 0302.

[0085] The cooling space is arranged in the electromagnetic isolation member, which can be closer to the heat source, so that the key heat generating elements in the drive control module 0300 can be precisely cooled, the working temperature of the power member 0301 and the capacitor member 0302 can be reduced, and the performance and stability of the power member 0301 and the capacitor member 0302 can be improved.

[0086] Through the cooling channel 0200, the cooling medium can flow more uniformly in the drive control module 0300 and the electric control module 0400, which can help to balance the temperature distribution of each part and reduce the occurrence of local overheating.

[0087] In a possible implementation, continuing to refer to Figure 1 , Figure 2 and Figure 4 , the partition 0101 is provided with a cooling flow path 0106, and the cooling flow path 0106 forms part of the cooling channel 0200.

[0088] Cooling flow path 0106 is disposed within the partition 0101, enabling simultaneous heat dissipation for components in both accommodating cavities. The distribution of cooling flow path 0106 within the partition 0101 cools both the first accommodating cavity 0103 and the second accommodating cavity 0104, thereby reducing the possibility of localized overheating.

[0089] By placing the cooling flow path 0106 inside the partition 0101, the structural space of the partition 0101 itself can be utilized to reduce the space occupied by placing the cooling channel 0200 in the accommodating cavity, thereby making the structure of the entire housing 1 more compact.

[0090] In one possible implementation, see [link to previous document]. Figure 1 , Figure 2 and Figure 4 As shown, the power component 0301 and the capacitor component 0302 are arranged along the direction of the first accommodating cavity 0103 and the second accommodating cavity 0104. The power component 0301 is located between the capacitor component 0302 and the partition 0101, and at least a portion of the cooling flow path 0106 is disposed opposite to at least a portion of the power component 0301. Alternatively, the capacitor component 0302 is located on the side of the power component 0301 closer to the partition 0101, and the cooling flow path 0106 is partially disposed opposite to the capacitor component 0302.

[0091] When the power component 0301 is closer to the partition 0101 than the capacitor component 0302, the cooling space can dissipate heat to the side of the power component 0301 that is closer to the capacitor component 0302, and the cooling flow path 0106 can dissipate heat to the side of the power component 0301 that is away from the capacitor component 0302, thereby improving the heat dissipation effect of the power component 0301.

[0092] The cases in which at least a portion of the cooling flow path 0106 is disposed opposite to at least a portion of the power component 0301 include: the orthographic projection of the power component 0301 on the partition 0101 is located in the cooling flow path 0106; a portion of the orthographic projection of the power component 0301 on the partition 0101 is located in the cooling flow path 0106; and a portion of the orthographic projection of the power component 0301 on the partition 0101 is located in a portion of the cooling flow path 0106.

[0093] When capacitor 0302 is located between power component 0301 and partition 0101, the cooling space can dissipate heat on the side of capacitor 0302 close to power component 0301, and the cooling flow path 0106 can dissipate heat on the side of capacitor 0302 away from power component 0301, thereby improving the heat dissipation effect of capacitor 0302.

[0094] The cases in which at least a portion of the cooling flow path 0106 is disposed opposite to at least a portion of the capacitor 0302 include: the orthographic projection of the capacitor 0302 on the partition 0101 is located in the cooling flow path 0106; a portion of the orthographic projection of the capacitor 0302 on the partition 0101 is located in the cooling flow path 0106; and a portion of the orthographic projection of the capacitor 0302 on the partition 0101 is located in a portion of the cooling flow path 0106.

[0095] In one possible implementation, see [link to previous document]. Figure 2 and Figure 4 As shown, the electronic control module 0400 includes a low-voltage control module 0401. The low-voltage control module 0401 is used to adjust the voltage to output different magnitudes of DC voltage, and the low-voltage control module 0401 is disposed in the second accommodating cavity 0104.

[0096] The low-voltage control module 0401 in the integrated controller 0100 can adjust the voltage in real time and accurately according to the system requirements, and output DC voltages of different magnitudes to ensure that each electronic component can obtain a stable and appropriate power supply voltage, ensure its stable performance, avoid problems such as abnormal operation and signal distortion caused by voltage fluctuations, and improve the operating efficiency and reliability of the entire electrical control system.

[0097] Integrating the low-voltage control module 0401 into the integrated controller 0100 eliminates the need for a separate installation space, which helps to achieve a high degree of integration of the electronic system.

[0098] Integrated design makes the wiring between the low-voltage control module 0401 and other related modules simpler and more orderly, reducing the number and length of external connection lines, reducing wiring complexity, saving wiring space, and reducing problems such as signal attenuation and electromagnetic interference caused by excessively long or messy wiring, thus improving the reliability and maintainability of the system.

[0099] For example, the low-voltage control module 0401 may be a DC module.

[0100] In one possible implementation, see Figure 1 , Figure 2 , Figure 4 and Figure 5 As shown, the integrated controller 0100 includes a cooling channel 0200. A cooling flow path 0106 is provided within the partition 0101, forming at least a portion of the cooling channel 0200. At least a portion of the low-voltage control module 0401 is disposed opposite to at least a portion of the cooling flow path 0106.

[0101] The low-pressure control module 0401 generates heat during operation. The low-pressure control module 0401 is arranged opposite to the cooling flow path 0106, so that heat can be directly and efficiently transferred to the cooling medium in the cooling flow path 0106. The cooling medium (e.g. coolant) continuously flows and can timely take away heat, thereby reducing the temperature of the low-pressure control module 0401 and reducing the performance degradation or even component damage caused by overheating.

[0102] The arrangement of at least part of the low-pressure control module 0401 opposite to at least part of the cooling flow path 0106 includes that: a projection of the low-pressure control module 0401 on the partition 0101 is located in the cooling flow path 0106; part of the projection of the low-pressure control module 0401 on the partition 0101 is located in the cooling flow path 0106; and part of the projection of the low-pressure control module 0401 on the partition 0101 is located in the cooling flow path 0106.

[0103] In a possible implementation, as shown in Figure 2 and Figure 5 , the electronic control module 0400 includes a steering control module 0402. The steering control module 0402 is configured to adjust and respond to the steering input of the driver. The steering control module 0402 is arranged in the second accommodating cavity 0104.

[0104] The steering control module 0402 can cooperate with the drive control module 0300 to adjust the size of the steering assist in real time according to the power state of the vehicle, so that the steering operation is more accurate and stable, and the control performance and driving safety of the vehicle are improved.

[0105] The integration of the steering control module 0402 in the integrated controller 0100 shortens the signal transmission path between the steering control module 0402 and other modules, reduces the signal transmission delay, and shortens the distance between the steering control module 0402 and the drive control module 0300.

[0106] The integration of the steering control module 0402 in the integrated controller 0100 avoids the need to separately arrange a housing and installation space for the steering control module 0402, which helps to reduce the overall volume and occupied space of the vehicle electronic system.

[0107] In a possible implementation, as shown in Figure 2 and Figure 5 , the electronic control module 0400 includes a safety control module 0403. The safety control module 0403 is configured to control the compressed air to provide stable and pressurized air. The safety control module 0403 is arranged in the second accommodating cavity 0104.

[0108] The integration of the safety control module 0403 in the integrated controller 0100 can improve the system performance and synergy. The safety control module 0403 integrated in the integrated controller 0100 can interact with other modules more efficiently.

[0109] The integration of the safety control module 0403 in the integrated controller 0100 avoids the need for a large installation space for the safety control module 0403 alone, and helps to achieve a compact design of the vehicle electronic system. Further, the number of connection harnesses between the safety control module 0403 and other modules is reduced.

[0110] In an example, the safety control module 0403 can be an air compressor module for controlling the provision of stable and pressurized compressed air.

[0111] In a possible implementation, referring to Figure 2 At least part of the steering control module 0402 is arranged opposite at least part of the cooling flow path 0106.

[0112] In this way, the cooling flow path 0106 can dissipate heat from the steering control module 0402.

[0113] During operation of the steering control module 0402, heat is generated by the electronic components.

[0114] The arrangement of at least part of the steering control module 0402 opposite at least part of the cooling flow path 0106 allows the heat to be quickly transferred to the cooling medium in the cooling flow path 0106, thereby dissipating heat from the steering control module 0402. This in turn reduces the risk of component performance degradation or damage due to excessive temperature.

[0115] In an example, the arrangement of at least part of the steering control module 0402 opposite at least part of the cooling flow path 0106 includes: the orthographic projection of the steering control module 0402 on the partition 0101 is located in the cooling flow path 0106; part of the orthographic projection of the steering control module 0402 on the partition 0101 is located in the cooling flow path 0106; and part of the orthographic projection of the steering control module 0402 on the partition 0101 is located in part of the cooling flow path 0106.

[0116] In a possible implementation, referring to Figure 2 At least part of the safety control module 0403 is arranged opposite at least part of the cooling flow path 0106.

[0117] In this way, the cooling flow path 0106 can dissipate heat from the safety control module 0403.

[0118] During operation of the safety control module 0403, heat is generated by the electronic components.

[0119] At least a portion of the safety control module 0403 is positioned opposite to at least a portion of the cooling flow path 0106, allowing heat to be quickly transferred to the cooling medium in the cooling flow path 0106, thereby dissipating heat from the safety control module 0403. This reduces the risk of component performance degradation or even damage due to excessively high temperatures.

[0120] For example, at least a portion of the safety control module 0403 is disposed relative to at least a portion of the cooling flow path 0106, including: the orthographic projection of the safety control module 0403 on the partition 0101 is located in the cooling flow path 0106; a portion of the orthographic projection of the safety control module 0403 on the partition 0101 is located in the cooling flow path 0106; and a portion of the orthographic projection of the safety control module 0403 on the partition 0101 is located in a portion of the cooling flow path 0106.

[0121] In one possible implementation, the safety control module 0403 and the steering control module 0402 are integrated on the same board.

[0122] In one possible implementation, see Figure 2 and Figure 5 As shown, the housing 1 also includes a second electromagnetic isolator 1044. The second electromagnetic isolator 1044 is located in the second accommodating cavity 0104 and connected to the partition 0101. The second electromagnetic isolator 1044 is disposed between the steering control module 0402 and the low-voltage control module 0401, and the second electromagnetic isolator 1044 is disposed between the safety control module 0403 and the low-voltage control module 0401.

[0123] Steering control module 0402, safety control module 0403 and low-voltage control module 0401 all generate a certain amount of electromagnetic radiation during operation.

[0124] The second electromagnetic isolator 1044 can block the propagation path of electromagnetic interference between these modules, reduce the electromagnetic coupling effect between them, thereby reducing the impact of electromagnetic interference from the low-voltage control module 0401 on the operation of the steering control module 0402 and the safety control module 0403, and thus improving the electromagnetic compatibility of the entire system.

[0125] The second electromagnetic isolator 1044 can also serve as a reinforcing rib in the second accommodating cavity 0104 of the housing 1, improving the structural strength of the housing 1 and reducing deformation of the housing 1. This, in turn, improves the stability of the integrated controller 0100.

[0126] During the manufacturing process, by setting the second electromagnetic isolation component 1044, the number of reinforcing ribs that need to be set in the second accommodating cavity 0104 can be reduced, the number of parts and assembly steps can be reduced, the production process can be simplified, the production efficiency can be improved, and the production cost can be reduced.

[0127] Exemplarily, the second electromagnetic isolation member 1044 can be an isolation wall.

[0128] With reference back to Figure 2 and Figure 5 The second electromagnetic isolation member 1044 is arranged between the air compressor IGBT 73, the steering IGBT 74, the air compressor and steering drive board 75, the control board 85 and the DC component 69, so as to reduce mutual interference between the components and improve EMC effect. The DC component 69 can be part of the low-voltage control module 0401.

[0129] In a possible implementation, with reference back to Figure 1 The integrated controller 0100 further comprises an inductor 39 arranged in the first accommodating cavity 0103. The shell 1 further comprises a third electromagnetic isolation member 1039 arranged in the first accommodating cavity 0103 and connected with the partition 0101. The third electromagnetic isolation member 1039 is arranged between the inductor 39 and the drive control module 0300.

[0130] The inductor 39 and the drive control module 0300 will generate certain electromagnetic radiation during operation.

[0131] The third electromagnetic isolation member 1039 and the second electromagnetic isolation member 1044 can block the propagation path of electromagnetic interference between the inductor 39 and the drive control module 0300, reduce the electromagnetic coupling effect between each other, and thus reduce the influence of electromagnetic interference of the low-voltage control module 0401 on the operation of the inductor 39 and the drive control module 0300, thereby improving the electromagnetic compatibility of the entire system.

[0132] The third electromagnetic isolation member 1039 can also serve as a reinforcing rib in the first accommodating cavity 0103 of the shell 1, improve the structural strength of the shell 1, and reduce the deformation of the shell 1. Thus, the stability of the integrated controller 0100 is improved.

[0133] During manufacturing, the third electromagnetic isolation member 1039 can reduce the number of reinforcing ribs that need to be arranged in the first accommodating cavity 0103, reduce the number of parts and assembly processes, simplify the production process, improve the production efficiency, and reduce the production cost.

[0134] Exemplarily, the third electromagnetic isolation member 1039 can be an isolation wall.

[0135] In a possible implementation, with reference back to Figure 1The integrated controller 0100 further comprises a DC filter 61. The DC filter 61 is arranged in the first accommodating cavity 0103. The shell 1 further comprises a fourth electromagnetic isolation member 1041 located in the first accommodating cavity 0103 and connected with the partition 0101. The fourth electromagnetic isolation member 1041 is arranged between the drive control module 0300 and the DC filter 61.

[0136] The DC filter 61 and the drive control module 0300 generate electromagnetic radiation during operation.

[0137] The fourth electromagnetic isolation member 1041 can block the propagation path of electromagnetic interference between the DC filter 61 and the drive control module 0300, reduce the electromagnetic coupling effect between them, thereby reducing the influence of electromagnetic interference of the low-voltage control module 0401 on the operation of the DC filter 61 and the drive control module 0300, and further improving the electromagnetic compatibility of the entire system.

[0138] The fourth electromagnetic isolation member 1041 can also serve as a reinforcing rib in the first accommodating cavity 0103 of the shell 1, improving the structural strength of the shell 1 and reducing the deformation of the shell 1. Further improve the stability of the integrated controller 0100.

[0139] During manufacturing, the fourth electromagnetic isolation member 1041 can reduce the number of reinforcing ribs that need to be arranged in the first accommodating cavity 0103, reducing the number of parts and assembly processes, simplifying the production process, improving production efficiency, and reducing production costs.

[0140] Exemplarily, the fourth electromagnetic isolation member 1041 can be a partition wall.

[0141] Referring to Figure 1 A fourth electromagnetic isolation member 1041 is arranged between the right drive IGBT assembly 28, the right drive capacitor assembly 32, the right drive three-phase assembly, the DC filter 61, the first main drive contactor-51, the second main drive contactor-52, the auxiliary contactor 53, and some DC copper bars, reducing mutual interference between the assemblies and effectively improving the EMC effect of the entire controller.

[0142] In a possible implementation, continuing to refer to Figure 1 The drive control module 0300 further comprises a contactor 0500 arranged in the first accommodating cavity 0103. The shell 1 further comprises a fifth electromagnetic isolation member 1042 located in the first accommodating cavity 0103 and connected with the partition 0101. The fifth electromagnetic isolation member 1042 is arranged between the contactor 0500 and the DC filter 61.

[0143] The DC filter 61 and the contactor 0500 generate electromagnetic radiation during operation.

[0144] The fifth electromagnetic isolation piece 1042 can block the propagation path of electromagnetic interference between the DC filter 61 and the contactor 0500, reduce the electromagnetic coupling effect between each other, thereby reducing the influence of electromagnetic interference of the low-voltage control module 0401 on the working of the DC filter 61 and the contactor 0500, and further improving the electromagnetic compatibility of the entire system.

[0145] The fifth electromagnetic isolation piece 1042 can also serve as a reinforcing rib in the first accommodating cavity 0103 of the shell 1, improve the structural strength of the shell 1, and reduce the deformation of the shell 1. Further improve the stability of the integrated controller 0100.

[0146] During the manufacturing process, by setting the fifth electromagnetic isolation piece 1042, the number of reinforcing ribs that need to be set in the first accommodating cavity 0103 can be reduced, the number of parts and assembly processes is reduced, the production process is simplified, the production efficiency is improved, and the production cost is reduced.

[0147] Illustratively, the fifth electromagnetic isolation piece 1042 can be an isolation wall.

[0148] In a possible implementation, continuing to refer to Figure 1 and Figure 4 , some isolation walls are also arranged in the shell 1. The isolation walls include: an upper box body left drive breather valve protection wall 1035, an upper box body right drive breather valve protection wall 1036, a lower box body left drive breather valve protection wall 1037, and a lower box body right drive breather valve protection wall 1038. The above isolation walls can play a protective role for the breather valve and reduce the situation of fire spouting through the breather valve when the components in the controller catch fire.

[0149] In a possible implementation, the shell 1 includes a third electromagnetic isolation piece 1039. The third electromagnetic isolation piece 1039 is arranged between the left drive IGBT assembly 4, the left drive capacitor assembly 8, the left drive three-phase assembly, and the inductor 39, reducing the signal mutual interference between the module assembly and the inductor, and effectively improving the EMC (electromagnetic compatibility) effect of the entire controller.

[0150] Referring to Figure 1 , the fifth electromagnetic isolation piece 1042 isolates the DC filter 61 from the components such as the first main drive contactor-51, the second main drive contactor-52, and the auxiliary contactor 53, which is conducive to improving the EMC effect.

[0151] Referring to Figure 1 , the air pressure steering assembly and the right drive board connection main control board wire harness isolation wall 1045 is arranged between the air pressure IGBT 73, the steering IGBT 74, the air pressure steering drive board 75, the control board 85, and the right drive board connection main control board wire harness 17, which is conducive to wire harness fixation and makes the entire layout more regular.

[0152] In a possible implementation, continuing to refer to Figure 2 and Figure 8 The integrated controller 0100 further comprises a current sampling assembly 0600, which is located in the second accommodating cavity 0104 and connected with the drive control module 0300 and the electronic control module 0400 respectively, and is configured to sample the current in the drive control module 0300 and the electronic control module 0400.

[0153] The current sampling assembly 0600 can collect the current information in the drive control module 0300 and the electronic control module 0400 in real time and accurately. The drive control module 0300 is responsible for the power output of the vehicle, and the current consumption thereof directly reflects the power energy consumption in the driving process of the vehicle. The electronic control module 0400 comprises a steering control module 0402, a safety control module 0403, a low-voltage control module 0401 and the like, and the current consumption of these modules reflects the energy consumption of the electronic system of the vehicle. By obtaining the current data of these modules in real time, the current consumption dynamics of the vehicle under different working conditions can be comprehensively understood.

[0154] The current sampling assembly 0600 samples the current of different modules respectively, and can clearly divide the energy consumption proportions of the power system and the electronic system respectively. Based on the energy consumption calculation result, the energy consumption cost of the whole vehicle can be intuitively presented.

[0155] In the operating vehicle, the energy consumption data recorded by the current sampling assembly 0600 can be used to compare the power consumption differences under different operating scenarios. Then, the operating scenario can be selected through the power consumption differences.

[0156] In a possible implementation, continuing to refer to Figure 2 The integrated controller 0100 further comprises an insurance assembly 0700. The insurance assembly 0700 is arranged in series in the drive control module 0300 and the electronic control module 0400. The side frame 0102 further encloses a third accommodating cavity 0105, which forms an opening at the end opposite to the partition 0101; and the insurance assembly 0700 is arranged in the third accommodating cavity 0105.

[0157] Placing each insurance assembly 0700 in the third accommodating cavity 0105, it is not necessary to design and install a space and a protection structure for each insurance assembly. In this way, the space can be saved, and the structure can be simplified. Meanwhile, arranging each insurance assembly together can make the wiring more concentrated and orderly, and reduce the length and complexity of the wiring.

[0158] In the assembly process of the integrated controller 0100, the fuse assembly 0700 is centrally placed in the third accommodating cavity 0105, which reduces the time for searching and installing the fuse in different positions, lowers the assembly difficulty, and thus facilitates and speeds up the installation operation.

[0159] When the fuse is blown due to overload, short circuit or other reasons, the centrally placed fuse assembly 0700 facilitates the rapid positioning of the fault fuse. There is no need to search for the fuse in each corner of the controller, and the replacement operation can be performed by only opening the third accommodating cavity 0105, which shortens the maintenance time, reduces the downtime of the vehicle, and improves the operation efficiency.

[0160] In a possible implementation, continuing to refer to Figure 2 The shell 1 comprises a third accommodating cavity isolation wall 1040. The third accommodating cavity isolation wall 1040 isolates the fuse in the third accommodating cavity 0105 from other components inside the shell 1, which can reduce the mutual interference between the components and improve the EMC. Meanwhile, the third accommodating cavity fixing seat 108 and each fuse can be fixed.

[0161] The above description of the embodiments of the present application will be further described below in terms of the connection mode between the components.

[0162] Referring to Figure 1 and Figure 2 , the shell 1 is arranged with two groups of cooling channels 0200.

[0163] As shown in Figure 1 , Figure 4 and Figure 5 , in the first group of cooling channels 0200, the cooling liquid flows from the left inlet pipe 64, enters the friction welding water channel portion of the rear wall of the electric control box body through the left inlet 1009, i.e. the left three-dimensional water channel A area 1010.

[0164] Referring to Figure 4 , the first group of cooling channels 0200 is connected to the left drive IGBT water channel inlet 2001 in the left water channel cover plate 2 of the electric control box body through the left three-dimensional water channel B area 1011, and the water flow cools the left drive IGBT assembly 4 and the upper part of the left drive capacitor assembly 8 by passing through the left drive IGBT water channel 2002. The water flow is guided out of the left water channel cover plate 2 of the electric control box body through the left drive IGBT water channel outlet 2004 and returns to the shell 1.

[0165] Referring to Figure 1 and Figure 5The cooling channel 0200 enters the friction welding water channel part of the rear wall of the electric control box through the left water inlet 1001, that is, the left three-dimensional water channel A area 1002, and then enters the friction welding water channel part of the lower cabinet of the electric control box through the left three-dimensional water channel B area 1003, that is, the air compressor steering cooling channel 1005.

[0166] As shown in Figure 1 , Figure 4 and Figure 5 , in the second group of cooling channels 0200, the cooling liquid enters the friction welding water channel part of the rear wall of the electric control box from the right water inlet 1001, that is, the left three-dimensional water channel A area 1002.

[0167] As shown in Figure 4 , the second group of cooling channels 0200 enters the friction welding water channel part of the lower cabinet of the electric control box through the right three-dimensional water channel B area 1003, that is, the air compressor steering cooling channel 1005.

[0168] As shown in Figure 1 and Figure 5 , the second group of cooling channels 0200 enters the friction welding water channel part of the lower cabinet of the electric control box through the right three-dimensional water channel B area 1003, that is, the air compressor steering cooling channel 1005.

[0169] By setting two groups of cooling channels 0200, two capacitors 0302 can be cooled respectively. The two groups of cooling channels 0200 work independently, which can more effectively remove the heat generated by the capacitors, and improve the overall heat dissipation efficiency.

[0170] The connection between the capacitors 0302 and the power components 0301 will be further described below.

[0171] In one possible implementation, the capacitors 0302 include a left drive capacitor assembly 8 and a right drive capacitor assembly 32. The power components 0301 include a left drive IGBT assembly 4 and a right drive IGBT assembly 28.

[0172] As shown in Figure 1 and Figure 6 , in the second group of cooling channels 0200, the cooling liquid enters the friction welding water channel part of the rear wall of the electric control box from the right water inlet 1001, that is, the left three-dimensional water channel A area 1002.As shown, the left drive IGBT assembly 4 is located above the left drive capacitor assembly 8, and an electric control box left waterway cover plate 2 is arranged between the two.

[0173] The left drive capacitor positive output copper bar 8001, the left drive capacitor negative output copper bar 8002, the left drive capacitor positive input copper bar 8003, the left drive capacitor negative input copper bar 8004, the left drive capacitor negative sampling terminal 8007, and the left drive capacitor positive sampling terminal 8008 are located on the other side of the capacitor.

[0174] Among them, the left drive capacitor positive output copper bar 8001 and the left drive capacitor negative output copper bar 8002 are separated by a left drive capacitor positive and negative output copper bar isolation rib 8005, and the left drive capacitor positive input copper bar 8003 and the left drive capacitor negative input copper bar 8004 are separated by a left drive capacitor positive and negative input copper bar isolation rib 8006.

[0175] In this way, the positive and negative copper bars are prevented from directly contacting each other to prevent short circuit failure.

[0176] Referring to Figure 1 and Figure 6 As shown, the positive and negative output copper bars of the left drive capacitor assembly 8 and the positive and negative input copper bars of the IGBT do not have screw connection hole positions, and the connection mode between them can be laser welding.

[0177] In this way, the positive and negative output copper bars of the capacitor and the positive and negative input copper bars of the IGBT can be made into a laminated busbar structure. The stray inductance of the power device during operation can be reduced, thereby reducing the ripple voltage, improving product reliability and work efficiency. Laser welding can reduce the insufficient connection between copper bars, thereby reducing the contact resistance and further reducing energy loss.

[0178] Referring to Figure 1 , Figure 2 and Figure 8 As shown.

[0179] Exemplarily, the sampling assembly 0600 can be a Hall plate 10501. The low-voltage control module 0401 includes a DC assembly 69.

[0180] The DC line fuse and Hall plate connection copper bar assembly 105 includes a Hall plate 10501, a total adapter copper bar 10502, a first air conditioner power distribution adapter copper bar 10503, a second air conditioner power distribution adapter copper bar 10504, a DC high-voltage adapter copper bar 10505, a steering high-voltage adapter copper bar 10506, an air compressor high-voltage adapter copper bar 10507, a defrosting power distribution adapter copper bar 10508, a PTC2 power distribution adapter copper bar 10509, and a PTC1 power distribution adapter copper bar 10510.

[0181] The main function of the assembly is line switching and current sampling, and the copper bar plays a connecting role. The Hall plate 10501 is used to sample the current in the switching copper bar. A plurality of chips are arranged on the Hall plate 10501, and a chip is arranged above each switching copper bar for sampling current, and the signals on the Hall plate are transmitted to the control panel 85 through the Hall plate connection main control panel wire harness 76.

[0182] Continuing to refer to Figure 1 and Figure 2 . The DC bus 131 enters the electric control box body 1 from the outside of the electric control box body through the DC bus via hole 1029, and the terminals of the DC bus 131 are connected to the DC input positive switching copper bar 6201 and the DC input negative switching copper bar 6202 in the DC input copper bar fixing seat 62.

[0183] Among them, the DC input positive switching copper bar 6201 and the DC input negative switching copper bar 6202 can be integrated in the DC input copper bar fixing seat 62 by one-piece injection molding. The DC input positive switching copper bar 6201 and the DC input negative switching copper bar 6202 pass through the DC filter 61 and are respectively connected to the DC input positive copper bar 57 and the DC input negative copper bar 38.

[0184] For example, the DC input positive copper bar 57 adopts a soft copper bar design and is made of 0.1mm copper sheet laminated and pressure welded. In this way, a part of the deformation amount is reserved, which can produce a small deformation during installation to offset part of the tolerance gap, reduce the stress on the copper bar, and facilitate the installation and lapping of the copper bars.

[0185] Continuing to refer to Figure 1 and Figure 2 . The DC input positive copper bar 57 is connected and fixed to four contactors: the main drive contactor 51, the main drive contactor 52, the auxiliary contactor 53, and the DC contactor 54. The DC input positive copper bar 57 is connected to the pre-charging group 110 through the DC bus pre-charging resistor high-voltage wire harness 59. The above four contactors and the high-voltage Hall plate 43 are connected to the control panel 85 through the control panel connection contactor and Hall assembly wire harness 135.

[0186] Continuing to refer to Figure 1 and Figure 2 . The other ends of the main drive contactor 51 and the main drive contactor 52 are connected to the main drive fuse assembly 40 through the main drive fuse input copper bar 42 and the main drive fuse input copper bar 42, and the other ends of the main drive fuse assembly 40 are connected to the inductor 39.

[0187] The two copper bar terminals connected to the main drive fuse assembly 40 in the inductor 39 are connected to the control panel 85 through the main control panel No. 1 main drive contactor bus pre-charging high-voltage wire harness 44 and the main control panel No. 2 main drive contactor bus pre-charging high-voltage wire harness 45.

[0188] Continuing to refer to Figure 1 and Figure 2 The other end of the inductor 39 is connected to the left drive capacitor assembly 8 and the right drive capacitor assembly 32 through the positive copper bar assembly 37 of the main drive capacitor input terminal.

[0189] Continuing to refer to Figure 1 and Figure 2 The upper part of the left drive capacitor assembly 8 is provided with a left drive discharge plate 18, and the upper part of the left drive IGBT assembly 4 is provided with a left drive board 14, which is connected to the control board 85 through the left drive board connection main control board wire harness 16.

[0190] The other end of the left drive IGBT assembly 4 is connected to the left drive W-phase copper bar 22, the left drive V-phase copper bar 23, and the left drive U-phase copper bar 24. The left drive three-phase copper bar needs to pass through the left drive Hall assembly 12 and the left drive three-phase magnetic ring 10, which can effectively improve the EMC effect.

[0191] The other end of the left drive three-phase copper bar is connected to the terminal of the left drive three-phase connector 20, which is turned out of the electric control box body 1 and connected to the motor three-phase terminal through the left drive three-phase connector 20.

[0192] The upper part of the right drive capacitor assembly 32 is provided with a right drive discharge plate 19, and the upper part of the right drive IGBT assembly 28 is provided with a right drive board 15, which is connected to the control board 85 through the right drive board connection main control board wire harness 17.

[0193] The other end of the right drive IGBT assembly 28 is connected to the right drive U-phase copper bar 25, the right drive V-phase copper bar 26, and the right drive U-phase copper bar 27. The right drive three-phase copper bar needs to pass through the right drive Hall assembly 113 and the right drive three-phase magnetic ring 11.

[0194] The other end of the right drive three-phase copper bar is connected to the terminal of the right drive three-phase connector 21, which is turned out of the electric control box body 1 and connected to the motor three-phase terminal through the right drive three-phase connector 21.

[0195] For example, the left drive three-phase copper bar and the right drive three-phase copper bar use soft copper material.

[0196] Specifically, it is made by laminating and pressure welding 0.1mm purple copper sheet. In this way, a certain deformation amount can be reserved, which can produce a small deformation during installation to offset part of the tolerance gap, reduce the stress on the copper bar, and facilitate the installation and lap joint of the copper bars.

[0197] For example, the integrated controller provided by the present application also reserves another more reliable three-phase assembly: grooves are opened on the two-phase copper bars on the outer side, two fuses are arranged on the side of the grooves, and an initiating device is arranged above the middle-phase copper bar for protecting the circuit.

[0198] Continuing to refer to Figure 2 , exemplary, the insurance components include but are not limited to: the upper-mounted insurance 109, the pre-charge resistor 110, the first air conditioner insurance 112, the second air conditioner insurance 113, the DC insurance 114, the steering insurance 115, the air pressure insurance 116, the defrosting insurance 117, the second PTC insurance 118, and the first PTC insurance 119.

[0199] The above-mentioned insurance components are all installed in the third accommodating cavity fixing seat 108 of the front wall, which is located in the third accommodating cavity 0105.

[0200] A third accommodating cavity side cover 132 is arranged at the opening, which is designed to save space compared to separate insurance, simplify the assembly process of the motor controller, facilitate the disassembly, assembly, and maintenance of the insurance, and further improve the production efficiency and facilitate the integration of the controller.

[0201] The auxiliary contactor 53 is connected with the upper-mounted insurance 109 through the upper-mounted insurance input copper bar 49, wherein the upper-mounted insurance input copper bar 49 is connected with the control panel 85 through the main control panel auxiliary contactor bus pre-charge high-voltage wire harness 50.

[0202] Exemplary, the third accommodating cavity fixing seat 108 of the front wall is injection molded with a copper bar. The input copper bar 49 is connected with the upper-mounted insurance output copper bar 47, and the other end of the upper-mounted insurance output copper bar 47 is connected with the upper-mounted connector 46 located on the left wall of the box.

[0203] Continuing to refer to Figure 1 and Figure 2 . The DC contactor 54 is connected with the first air conditioner insurance 112, the second air conditioner insurance 113, the DC insurance 114, the steering insurance 115, the air pressure insurance 116, the defrosting insurance 117, the second PTC insurance 118, and the first PTC insurance 119 through the DC contactor output copper bar 58.

[0204] Among them, the DC contactor output copper bar 58 is connected with the control panel 85 through the main control panel DC contactor bus pre-charge high-voltage wire harness 60.

[0205] Among them, the other end of the first air conditioner insurance 112 and the second air conditioner insurance 113 is connected with the air conditioner connector 1-94 and the air conditioner connector 2-95 through the first air conditioner power distribution adapter copper bar 10503 and the second air conditioner power distribution adapter copper bar 10504 in the DC line insurance and Hall panel connection copper bar assembly 105, and the first air conditioner power distribution positive wire harness 102 and the second air conditioner power distribution positive wire harness 104 which pass through the first air conditioner magnetic ring-98 and the second air conditioner magnetic ring-99.

[0206] The other end of the DC fuse 114 is connected to the DC high voltage transfer copper bar 10505 in the DC line fuse and Hall plate connecting copper bar assembly 105 and a DC high voltage positive wire harness 106 to the DC assembly 69.

[0207] The other end of the steering fuse 115 is connected to the steering high voltage transfer copper bar 10506 in the DC line fuse and Hall plate connecting copper bar assembly 105 and a steering high voltage positive wire harness 78 to the 2PIN PCB connector in the air compressor steering drive board 75.

[0208] The other end of the air compressor fuse 116 is connected to the air compressor high voltage transfer copper bar 10507 in the DC line fuse and Hall plate connecting copper bar assembly 105 and an air compressor high voltage positive wire harness 77 to another 2PIN PCB connector on the air compressor steering drive board 75, which is connected to the control board 85 through a wire harness, and the steering motor three-phase wire harness 86 is connected to the steering connector 89 after passing through the steering magnetic ring 83 in the air compressor steering magnetic ring fixing seat 87.

[0209] The air compressor motor three-phase wire harness 81 is connected to the air compressor connector 88 after passing through the air compressor magnetic ring 82 in the air compressor steering magnetic ring fixing seat 87.

[0210] Continuing to refer to Figure 1 , Figure 2 shown, and in combination with Figure 8 shown, the other end of the defrosting fuse 117 is connected to the DCM (defrosting) power distribution connector 128 through the defrosting power distribution transfer copper bar 10508 and a defrosting power distribution negative wire harness 120 that passes through the defrosting magnetic ring in the PTC and defrosting connector magnetic ring fixing seat 127. The PTC and defrosting connector magnetic ring fixing seat 127 contains a defrosting magnetic ring and two PTC magnetic rings.

[0211] The other end of the first PTC fuse 119 is connected to the PTC1 power distribution connector 130 through the PTC1 power distribution transfer copper bar 10510 in the DC line fuse and Hall plate connecting copper bar assembly 105 and a first PTC power distribution negative wire harness 122 that passes through the PTC1 magnetic ring in the PTC and defrosting connector magnetic ring fixing seat 127.

[0212] The other end of the second PTC fuse 118 is connected to the PTC2 power distribution connector 129 through the PTC2 power distribution transfer copper bar 10509 in the DC line fuse and Hall plate connecting copper bar assembly 105 and a second PTC power distribution negative wire harness 121.

[0213] The Hall plate in the DC line fuse and Hall plate connecting copper bar assembly 105 is connected to the control board 85 through the Hall plate connecting main control board wire harness 76.

[0214] The DC input negative copper bar 38 has four terminals, the first terminal is connected with the DC input negative adapter copper bar 6202 in the DC input copper bar fixing seat 62, the second terminal is connected with the DC negative adapter copper bar assembly 55, the third terminal is connected with the right drive capacitor assembly 32, and the fourth terminal is connected with the left drive capacitor assembly 8.

[0215] The DC negative adapter copper bar assembly 55 also has four terminals, the second terminal is connected with the DC line fuse and Hall plate connecting copper bar assembly 105 through the DC negative adapter copper column fixing seat 56, the third terminal is a reserved terminal, and the fourth terminal is connected with the upper mounting connector 46 through the copper bar integrally injection molded in the upper mounting connector negative connecting copper bar assembly 48.

[0216] The copper bar connected with the DC negative adapter copper column fixing seat 56 in the DC line fuse and Hall plate connecting copper bar assembly 105 has nine terminals.

[0217] The first terminal is connected with the connector on the control panel 85 through the main control panel high-voltage bus negative wire harness 126.

[0218] The second terminal is connected with the 2PIN type PCB connector on the air pressure steering drive panel 75 through the air pressure high-voltage negative wire harness 79.

[0219] The third terminal is connected with another 2PIN type PCB connector on the air pressure steering drive panel 75 through the steering high-voltage negative wire harness 80.

[0220] The fourth terminal is connected with the DC assembly 69 through the DC high-voltage negative wire harness 107.

[0221] The fifth terminal is connected with the first PTC (battery water cooling / heating) distribution connector 130 through a first PTC distribution positive wire harness 125 which passes through the PTC and defrosting plug magnetic ring fixing seat 127.

[0222] The sixth terminal is connected with the second PTC (electric heating) distribution connector 129 through a second PTC distribution positive wire harness 124 which passes through the PTC and defrosting plug magnetic ring fixing seat 127.

[0223] The seventh terminal is connected with the DCM (defrosting) distribution connector 128 through a defrosting distribution positive wire harness 123 which passes through the PTC and defrosting plug magnetic ring fixing seat 127.

[0224] The eighth terminal is connected with the first air conditioner connector 94 through a first air conditioner distribution negative wire harness 101 which passes through the first air conditioner magnetic ring-98.

[0225] The ninth terminal is connected with the second air conditioner connector 95 through a second air conditioner distribution negative wire harness 103 which passes through the second air conditioner magnetic ring-99.

[0226] Exemplarily, the magnetic ring assembly is arranged at each interface position, so that the EMC effect of the motor controller is effectively improved.

[0227] The low-voltage connector 93 is welded on the low-voltage connector adapter plate 91, the low-voltage connector adapter plate 91 is connected with the control panel through a wire harness, the DC assembly wire harness 72 and the DC output connection control panel low-voltage power supply wire harness 71 are connected with the DC assembly 69 through the control panel.

[0228] Although the application has been described in connection with embodiments thereof, modifications and / or additions, which do not depart from the spirit and scope of the application, will occur to those skilled in the art. For example, the application has been described with reference to particular means for carrying out the various functions. Of course, the means disclosed are only examples and one skilled in the art will understand that other means can be used to carry out the described functions without departing from the scope and spirit of the application. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite articles "a" or "an" do not exclude a plurality. A single processor or other unit can fulfill the functions of several items recited in the claims. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. The reference signs in the claims should not be construed as limiting the scope of the application.

[0229] Although the application has been described in connection with specific embodiments thereof, it will be evident for those skilled in the art that various modifications and combinations are possible without departing from the spirit and scope of the application. Accordingly, the description and drawings are to be regarded as illustrative in nature and are not to be taken as limiting the scope of the application as defined in the appended claims. Obviously, many modifications and variations of this application are possible in light of its teachings. It is, therefore, to be understood that within the scope of the claims and their equivalents, the application can be practiced otherwise than as specifically described. Thus, the application should not be limited by any of the above described embodiments.

[0230] The above merely illustrates the specific implementation of the present application, but the protection scope of the present application is not limited to this. Any skilled person in the art can easily think of changes or replacements within the technical range disclosed by the present application, which should be covered in the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

Claims

1. An integrated controller (0100) characterized by, The integrated controller (0100) for a vehicle comprises a housing (1) and a drive control module (0300) and an electronic control module (0400) arranged in the housing (1).

2. The integrated controller (0100) according to claim 1, characterized in that The housing (1) comprises: a partition (0101) and a side frame (0102) arranged around the partition (0101), the partition (0101) separating a space in the side frame (0102) into a first accommodating cavity (0103) and a second accommodating cavity (0104); the drive control module (0300) is arranged in the first accommodating cavity (0103); and the electronic control module (0400) is arranged in the second accommodating cavity (0104).

3. The integrated controller (0100) according to claim 2, characterized in that, The drive control module (0300) comprises: a power component (0301); a capacitor component (0302) connected with the power component (0301), and the capacitor component (0302) and the power component (0301) are arranged along the arrangement direction of the first accommodating cavity (0103) and the second accommodating cavity (0104).

4. The integrated controller (0100) according to claim 3, characterized in that The drive control module (0300) comprises: a first electromagnetic isolation component (0201) arranged between the power component (0301) and the capacitor component (0302).

5. The integrated controller (0100) according to claim 4, characterized in that, The first electromagnetic isolation component (0201) is provided with a cooling space; the integrated controller (0100) comprises: a cooling channel (0200) for dissipating heat of the drive control module (0300) and the electronic control module (0400); and the cooling space forms a part of the cooling channel (0200).

6. The integrated controller (0100) according to claim 5, wherein: a cooling flow path (0106) is arranged in the partition (0101), the cooling flow path (0106) is in communication with the cooling space, and the cooling flow path (0106) forms a part of the cooling channel (0200).

7. The integrated controller (0100) according to claim 6, wherein: the power component (0301) is located between the partition (0101) and the capacitor component (0302); at least part of the power component (0301) is arranged opposite to at least part of the cooling flow path (0106) along the arrangement direction of the first accommodating cavity (0103) and the second accommodating cavity (0104); alternatively, the capacitor component (0302) is located between the power component (0301) and the partition (0101); at least part of the capacitor component (0302) is arranged opposite to at least part of the cooling flow path (0106) along the arrangement direction of the first accommodating cavity (0103) and the second accommodating cavity (0104).

8. The integrated controller (0100) according to claim 2, characterized in that, The electronic control module (0400) comprises: a low-voltage control module (0401) for outputting a direct-current voltage, and the low-voltage control module (0401) is arranged in the second accommodating cavity (0104).

9. The integrated controller (0100) according to claim 8, characterized in that The integrated controller (0100) comprises a cooling channel (0200); a cooling flow path (0106) is arranged in the partition (0101), and the cooling flow path (0106) forms at least a partial section of the cooling channel (0200); and at least a part of the low-voltage control module (0401) is arranged opposite to at least a part of the cooling flow path (0106) along the arrangement direction of the first accommodating cavity (0103) and the second accommodating cavity (0104).

10. The integrated controller (0100) according to claim 9, characterized in that, The electric control module (0400) comprises: a steering control module (0402) arranged in the second accommodating cavity (0104).

11. The integrated controller (0100) according to claim 10, characterized in that The electric control module (0400) comprises: a safety control module (0403) for controlling the charging and discharging of compressed air; the safety control module (0403) is arranged in the second accommodating cavity (0104).

12. The integrated controller (0100) according to claim 11, characterized in that At least a part of the steering control module (0402) and / or at least a part of the safety control module (0403) is arranged opposite to at least a part of the cooling flow path (0106) along the arrangement direction of the first accommodating cavity (0103) and the second accommodating cavity (0104).

13. The integrated controller (0100) according to claim 11, characterized in that, The shell (1) further comprises: a second electromagnetic isolation member (1044) arranged in the second accommodating cavity (0104) and connected with the partition (0101); the second electromagnetic isolation member (1044) is arranged between the steering control module (0402) and the low-voltage control module (0401), and the second electromagnetic isolation member (1044) is arranged between the safety control module (0403) and the low-voltage control module (0401).

14. The integrated controller (0100) according to claim 3, characterized in that, The integrated controller (0100) further comprises an inductor (39) arranged in the first accommodating cavity (0103); the shell (1) further comprises: a third electromagnetic isolation member (1039) arranged in the first accommodating cavity (0103) and connected with the partition (0101); the third electromagnetic isolation member (1039) is arranged between the inductor (39) and the drive control module (0300).

15. The integrated controller (0100) according to claim 2, characterized in that, The integrated controller (0100) further comprises a DC filter (61) arranged in the first accommodating cavity (0103); the shell (1) further comprises: a fourth electromagnetic isolation member (1041) arranged in the first accommodating cavity (0103) and connected with the partition (0101); the fourth electromagnetic isolation member is arranged between the drive control module (0300) and the DC filter (61).

16. The integrated controller (0100) according to claim 15, characterized in that The drive control module (0300) further comprises a contactor (0500) arranged in the first accommodating cavity (0103); the shell (1) further comprises: A fourth electromagnetic isolation piece (1042) is arranged in the first accommodating cavity (0103) and connected with the partition (0101); the fourth electromagnetic isolation piece (1042) is arranged between the contactor (0500) and the DC filter (61).

17. The integrated controller (0100) according to claim 2, characterized in that, The integrated controller (0100) further comprises: A current sampling assembly (0600) is arranged in the second accommodating cavity (0104); the current sampling assembly (0600) is connected with the drive control module (0300) and the electric control module (0400) respectively; the current sampling assembly (0600) is used for sampling current in the drive control module (0300) and the electric control module (0400).

18. The integrated controller (0100) according to claim 2, characterized in that, The integrated controller (0100) further comprises: an insurance assembly (0700) connected with the drive control module (0300) and the electric control module (0400); The periphery of the side frame (0102) is further provided with a third accommodating cavity (0105); an opening is formed at one end of the third accommodating cavity (0105) which is opposite to the side frame (0102); the insurance assembly (0700) is arranged in the third accommodating cavity (0105).

19. A vehicle characterized by comprising: The integrated controller (0100) comprises any one of claims 1-18.

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