All-in-one high-voltage controller and vehicle

Abstract

The utility model discloses an all-in-one high-voltage controller and a vehicle, and the all-in-one high-voltage controller comprises an electromagnetic compatibility filter, a bus capacitor, a power distribution unit, a motor controller driving module, a vehicle-mounted charger, a DC-DC converter driving module, and a main control module which are fixedly disposed in a vehicle-mounted battery pack. The main control module comprises a whole vehicle controller, a motor controller control unit, a vehicle-mounted charger and a direct current-direct current converter control unit. The electromagnetic compatibility filter, the bus capacitor, the power distribution unit, the motor controller driving module, the vehicle-mounted charger, the DC-DC converter driving module and the main control module are all integrated in the vehicle-mounted battery pack, so that all the components can share part of structural parts and cooling waterways; the volume utilization rate and the power density of the system are improved, the lengths of a high-voltage wire harness, a copper bar, a cooling pipeline and a power supply line required by the high-voltage system are reduced, and the cost is greatly reduced.

Description

Technical Field

[0001] This utility model relates to the field of integrated power controller technology, and more specifically, to an all-in-one high-voltage controller and vehicle. Background Technology

[0002] Currently, the core components of new energy vehicles include: power batteries, electric drives, PDUs (Power Distribution Units), DC / DC converters (Direct Current-to-Direct Current Converters), and OBCs (On-Board Chargers). The mainstream technical solutions currently available are as follows:

[0003] 1. Split design, each component is an independent controller connected via a high-voltage wiring harness;

[0004] 2. Integrating OBC, DC-DC, and PDU saves on some high-voltage wiring harnesses;

[0005] 3. Integrate OBC, DC-DC, PDU and motor drive together.

[0006] In the separate design, each controller has its own housing and cooling channels, making heat dissipation impossible to integrate, and the cost of structural components and wiring harnesses also increases. On the other hand, integrating the OBC, DC-DC, PDU, or integrating them with the motor and electric drive can easily lead to a long transmission path between the battery and the high-power electrical system, and requires a separate cooling pipeline and thermal management system for the integrated controller, which adds extra cost. Utility Model Content

[0007] This utility model provides an all-in-one high-voltage controller and vehicle to reduce costs. The specific technical solution is as follows:

[0008] In a first aspect, this utility model provides an all-in-one high-voltage controller, comprising:

[0009] Electromagnetic compatibility filter, bus capacitor, power distribution unit, motor controller drive module, on-board charger and DC-DC converter drive module and main control module are fixedly installed inside the vehicle battery pack;

[0010] The power distribution unit is electrically connected to the electromagnetic compatibility filter, the electromagnetic compatibility filter is electrically connected to the bus capacitor, and the bus capacitor is electrically connected to the motor controller drive module, the on-board charger, and the DC-DC converter drive module, respectively.

[0011] The main control module includes a vehicle controller, a motor controller control unit, and an on-board charger and DC-DC converter control unit. The motor controller control unit and the on-board charger and DC-DC converter control unit are all electrically connected to the vehicle controller. The motor controller control unit is electrically connected to the motor controller drive module, and the on-board charger and DC-DC converter control unit is electrically connected to the on-board charger and DC-DC converter drive module.

[0012] The motor controller control unit is used to control the motor controller drive module, and the on-board charger and DC-DC converter control unit is used to control the on-board charger and DC-DC converter drive module.

[0013] Optionally, the on-board charger and DC-DC converter drive module includes a power factor correction circuit, a capacitor-inductor circuit, and a DC-DC converter circuit that are connected in sequence.

[0014] Optionally, the all-in-one high-voltage controller further includes a first switch, a second switch, a third switch, and a fourth switch;

[0015] The high-voltage bus of the motor controller drive module is electrically connected to the first switch and the second switch respectively. The first switch is electrically connected to the bus of the vehicle battery pack, and the second switch is electrically connected to the DC bus support capacitor of the power factor correction circuit. When the motor controller drive module is running, the first switch is closed and the second switch is open. When the motor controller drive module is not running and is in power factor correction mode, the first switch is open and the second switch is closed.

[0016] The inductor in the power factor correction circuit is the inductor of the motor. The three phases of the motor are electrically connected to the third switch and the fourth switch respectively. When the motor is running, both the third switch and the fourth switch are closed. When the motor is not running and is in power factor correction mode, both the third switch and the fourth switch are open.

[0017] Optionally, the all-in-one high-voltage controller may also include a transformer;

[0018] The inductance of the capacitor-inductor circuit and the inductance of the DC-DC converter circuit are both wound around the magnetic core of the transformer.

[0019] Optionally, the vehicle controller includes a vehicle dynamic control unit and a vehicle electronic stability system.

[0020] Optionally, the main control module may also include a battery management system and a thermal management system.

[0021] Optionally, the all-in-one high-voltage controller also includes a fast-charging connector, an on-board charger connector, a vehicle low-voltage connector, a high-voltage AC connector, and a low-voltage DC connector installed on the peripheral interface of the vehicle battery pack.

[0022] The power distribution unit is electrically connected to the fast charging connector, the on-board charger and the DC-DC converter drive module are electrically connected to the on-board charger connector and the low-voltage DC connector, respectively, the main control module is electrically connected to the vehicle low-voltage connector, and the motor controller drive module is electrically connected to the high-voltage AC connector.

[0023] Optionally, the all-in-one high-voltage controller also includes a high-voltage DC connector that is fixedly installed inside the vehicle battery pack;

[0024] The power distribution unit is electrically connected to the high-voltage DC connector.

[0025] Optionally, the all-in-one high-voltage controller also includes an electric heating film connector that is fixedly installed inside the vehicle battery pack;

[0026] The power distribution unit is electrically connected to the electric heating film connector.

[0027] Secondly, this utility model provides a vehicle, comprising:

[0028] Vehicle body, onboard battery pack, and all-in-one high-voltage controller;

[0029] The multi-functional high-voltage controller is fixedly installed inside the vehicle battery pack, and the vehicle battery pack is fixedly installed inside the vehicle body. The multi-functional high-voltage controller is a multi-functional high-voltage controller as described in any one of the first aspects.

[0030] As described above, the multi-functional high-voltage controller provided by this utility model includes an electromagnetic compatibility filter, a bus capacitor, a power distribution unit, a motor controller drive module, an on-board charger and DC-DC converter drive module, and a main control module, all fixedly installed inside the vehicle battery pack. The power distribution unit is electrically connected to the electromagnetic compatibility filter, the electromagnetic compatibility filter is electrically connected to the bus capacitor, and the bus capacitor is electrically connected to the motor controller drive module, the on-board charger and the DC-DC converter drive module, respectively. The main control module includes a vehicle controller, a motor controller control unit, and an on-board charger and DC-DC converter control unit. The motor controller control unit and the on-board charger and DC-DC converter control unit are all electrically connected to the vehicle controller. The motor controller control unit is electrically connected to the motor controller drive module, and the on-board charger and DC-DC converter control unit is electrically connected to the on-board charger and DC-DC converter drive module. The motor controller control unit controls the motor controller drive module, and the on-board charger and DC-DC converter control unit controls the on-board charger and DC-DC converter drive module. Therefore, by integrating the electromagnetic compatibility filter, bus capacitor, power distribution unit, motor controller drive module, on-board charger, DC-DC converter drive module, and main control module into the on-board battery pack, the components can share some structural parts and cooling water circuits, improving the system's volume utilization and power density, reducing the length of high-voltage wiring harnesses, copper busbars, cooling pipes, and power supply lines required by the high-voltage system, and greatly reducing costs.

[0031] The innovative aspects of this utility model embodiment include:

[0032] 1. By integrating the electromagnetic compatibility filter, bus capacitor, power distribution unit, motor controller drive module, on-board charger, DC-DC converter drive module, and main control module into the on-board battery pack, the components can share some structural parts and cooling water circuits, improving the system volume utilization and power density, reducing the length of high-voltage wiring harnesses, copper busbars, cooling pipes, and power supply lines required by the high-voltage system, and greatly reducing costs.

[0033] 2. Because the electromagnetic compatibility filter, bus capacitor, power distribution unit, motor controller drive module, on-board charger, DC-DC converter drive module and main control module are all integrated inside the on-board battery pack in this utility model, each component is inside the on-board battery pack, which is the power supply end. This greatly reduces the transmission distance between each component and the power supply end, reduces transmission loss and improves efficiency.

[0034] 3. The on-board charger and DC-DC converter drive module achieve bidirectional energy exchange through a capacitor-inductor circuit. A single on-board charger and DC-DC converter drive module can simultaneously enable external charging stations to charge the vehicle, the vehicle to charge external loads or other vehicles, and the vehicle to interact with the power grid. This gives the on-board battery pack richer functionality. The scenario of the vehicle charging external loads or other vehicles can be used for camping or roadside assistance. The interaction between the vehicle and the power grid can be used for peak shaving and valley filling, charging during off-peak hours and selling the electricity back to the grid during peak hours, thus maximizing the utilization rate of the on-board battery pack.

[0035] 4. By setting the high-voltage bus of the motor controller drive module to be electrically connected to the first switch and the second switch respectively, the first switch to be electrically connected to the bus of the vehicle battery pack, the second switch to be electrically connected to the bus support capacitor of the power factor correction circuit, and replacing the inductor in the power factor correction circuit with the inductor of the motor, the function of the power factor correction circuit can be realized using existing components on the vehicle, reducing size and cost.

[0036] 5. By winding the inductors of both the capacitor and inductor circuits and the DC-DC converter circuits around the core of the transformer, magnetic integration is achieved. This allows the high voltage of the vehicle battery pack to be converted to the low voltage of the DC-DC converter circuit using the same transformer, and bidirectional energy exchange is achieved by sharing the core of a single transformer, greatly reducing size and cost.

[0037] 6. The multi-functional high-voltage controller provided in this embodiment can integrate the vehicle dynamic control unit, the vehicle electronic stability system and other power / high voltage related functions with the motor controller control unit in the same controller at the control level. This can significantly shorten the control link between coupled control modules, thereby improving dynamic control performance and reducing control delay from hundreds of milliseconds to milliseconds.

[0038] 7. The main control module also integrates the battery management system and the thermal management system, both of which are related to the high-voltage power domain. This achieves the integration of all systems related to the high-voltage power domain, enabling the all-in-one high-voltage controller to perform various functions related to the high-voltage power domain.

[0039] 8. By installing fast charging connectors, on-board charger connectors, vehicle low-voltage connectors, high-voltage AC connectors, and low-voltage DC connectors on the external interface of the vehicle battery pack, each connector is led out to the external interface of the vehicle battery pack, while the wiring harnesses related to each connector are inside the vehicle battery pack. This reduces the complexity and usage of external wiring harnesses, copper busbars, and cooling pipes, thereby reducing raw material costs and assembly costs.

[0040] 9. High-voltage DC power is supplied to the vehicle battery pack by setting up a high-voltage DC connector.

[0041] 10. Heating of the vehicle battery pack is achieved by setting up an electric heating film connector.

[0042] 11. The vehicle provided in this embodiment of the utility model includes a body, an on-board battery pack, and a multi-functional high-voltage controller. The multi-functional high-voltage controller integrates an electromagnetic compatibility filter, bus capacitor, power distribution unit, motor controller drive module, on-board charger, DC-DC converter drive module, and main control module inside the on-board battery pack. This allows the components to share some structural parts and cooling water circuits, improving the system's volume utilization and power density. It also reduces the length of high-voltage wiring harnesses, copper busbars, cooling pipes, and power supply lines required by the high-voltage system, significantly reducing costs.

[0043] Of course, implementing any product or method of this utility model does not necessarily require achieving all of the advantages described above at the same time. Attached Figure Description

[0044] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0045] Figure 1 A schematic diagram of a multi-in-one high-voltage controller provided in an embodiment of this utility model;

[0046] Figure 2 Another structural schematic diagram of the all-in-one high-voltage controller provided in this embodiment of the utility model;

[0047] Figure 3 A partial power topology diagram of the all-in-one high-voltage controller provided in this embodiment of the utility model;

[0048] Figure 4 A schematic diagram illustrating the implementation effect of the all-in-one high-voltage controller provided in this embodiment of the utility model.

[0049] Figures 1-4The components are as follows: 1. On-board battery pack; 11. Fast charging connector; 12. On-board charger connector; 13. Vehicle low-voltage connector; 14. High-voltage AC connector; 15. Low-voltage DC connector; 16. High-voltage DC connector; 17. Electric heating film connector; 2. Electromagnetic compatibility filter; 3. Bus capacitor; 4. Power distribution unit; 5. Motor controller drive module; 6. On-board charger and DC-DC converter drive module; 61. Power factor correction circuit; 611. DC bus support capacitor; 62. Capacitor and inductor circuit; 63. DC-DC converter circuit; 7. Main control module; 71. Vehicle controller; 72. Motor controller control unit; 73. On-board charger and DC-DC converter control unit; 74. Battery management system; 75. Thermal management system; 8. Third switch; 9. Fourth switch; 10. Magnetic core. Detailed Implementation

[0050] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only a part of the embodiments of the present utility model, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the scope of protection of the present utility model.

[0051] It should be noted that the terms "comprising" and "having," and any variations thereof, in the embodiments and drawings of this utility model are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that includes a series of steps or units is not limited to the steps or units listed, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products, or devices.

[0052] This utility model discloses an all-in-one high-voltage controller and vehicle, which can reduce costs. The following is a detailed description of this utility model embodiment.

[0053] Figure 1 This is a schematic diagram of a multi-functional high-voltage controller provided in an embodiment of the present invention.

[0054] Figure 2 This is another structural schematic diagram of the all-in-one high-voltage controller provided in an embodiment of the present invention.

[0055] See Figure 1 and Figure 2 The present invention provides an all-in-one high-voltage controller comprising an electromagnetic compatibility filter 2, a bus capacitor 3, a power distribution unit 4, a motor controller drive module 5, an on-board charger and DC-DC converter drive module 6, and a main control module 7, all fixedly installed inside the vehicle battery pack 1.

[0056] exist Figure 1 For ease of reference, electromagnetic compatibility filter 2 is referred to as EMC (Electromagnetic Compatibility) filter, power distribution unit 4 as PDU (Power Distribution Unit), motor controller drive module 5 as MCU (Motor Controller Unit) drive module, and on-board charger and DC-DC converter drive module 6 as OBC / DCDC (On Board Charger / Direct Current-to-Direct Current Converter) drive module. Figure 1 The EMC filter, bus capacitor 3, and PDU are grouped together in the diagram for illustrative purposes only and do not represent that the three components are integrated.

[0057] The power distribution unit 4 is electrically connected to the electromagnetic compatibility filter 2, the electromagnetic compatibility filter 2 is electrically connected to the bus capacitor 3, and the bus capacitor 3 is electrically connected to the motor controller drive module 5, the on-board charger, and the DC-DC converter drive module 6. Specifically, the bus capacitor 3 is electrically connected to each component via copper busbars.

[0058] Among them, the motor controller drive module 5 is used to invert the external high-voltage DC power into three-phase AC power to power the vehicle's motor and drive the motor to rotate; the on-board charger and DC-DC converter drive module 6 is used to invert the external AC power into DC power, boost it to high voltage to charge the on-board battery pack 1, and reduce the high voltage of the on-board battery pack 1 to low voltage to power the vehicle's low-voltage system.

[0059] See also Figure 1 The main control module 7 includes a vehicle controller 71, a motor controller control unit 72, and an on-board charger and DC-DC converter control unit 73. The motor controller control unit 72 and the on-board charger and DC-DC converter control unit 73 are all electrically connected to the vehicle controller 71. The motor controller control unit 72 is electrically connected to the motor controller drive module 5, and the on-board charger and DC-DC converter control unit 73 is electrically connected to the on-board charger and DC-DC converter drive module 6.

[0060] Figure 1 As a schematic diagram, only the motor controller drive module 5 and the on-board charger and DC-DC converter drive module 6 are shown, all of which are electrically connected to the main control module 7. And for ease of viewing, Figure 1In this context, the vehicle controller 71 is referred to as VCU (Vehicle Control Unit), the motor controller control unit 72 is referred to as MCU control, and the on-board charger and DC-DC converter control unit 73 is referred to as OBC / DCDC control. Figure 1 It also has an inlet and an outlet for the vehicle battery pack 1.

[0061] Specifically, the vehicle controller 71, the motor controller control unit 72, and the on-board charger and DC-DC converter control unit 73 are integrated on the same PCB (Printed Circuit Board). Therefore, the vehicle controller 71, the motor controller control unit 72, and the on-board charger and DC-DC converter control unit 73 are connected by on-board signals.

[0062] Each control unit and its corresponding drive module are located on different PCB boards. Therefore, the connection between each control unit and its corresponding drive module is an inter-board signal connection. That is, the motor controller control unit 72 and the motor controller drive module 5 are inter-board signal connections, and the on-board charger and DC-DC converter control unit 73 and the on-board charger and DC-DC converter drive module 6 are inter-board signal connections. However, whether it is an intra-board signal connection or an inter-board signal connection, it is a low-voltage connection.

[0063] Among them, the motor controller control unit 72 is used to control the motor controller drive module 5, and the on-board charger and DC-DC converter control unit 73 is used to control the on-board charger and DC-DC converter drive module 6.

[0064] In other words, the motor controller drive module 5, as well as the on-board charger and DC-DC converter drive module 6, are all controlled by the main control module 7.

[0065] Specifically, the main control module 7 runs the core algorithm of the all-in-one assembly. Based on the instruction requirements of the internally integrated vehicle controller 71, it sends corresponding PWM (Pulse Width Modulation) control commands to the motor controller drive module 5 and the on-board charger and DC-DC converter drive module 6 through the motor controller control unit 72 and the on-board charger and DC-DC converter control unit 73, respectively, to perform corresponding control.

[0066] In summary, the multi-functional high-voltage controller provided by this utility model embodiment includes an electromagnetic compatibility filter 2, a bus capacitor 3, a power distribution unit 4, a motor controller drive module 5, an on-board charger and DC-DC converter drive module 6, and a main control module 7, all fixedly installed inside the vehicle battery pack 1. The power distribution unit 4 is electrically connected to the electromagnetic compatibility filter 2, the electromagnetic compatibility filter 2 is electrically connected to the bus capacitor 3, and the bus capacitor 3 is electrically connected to the motor controller drive module 5 and the on-board charger and DC-DC converter drive module 6, respectively. The main control module 7 includes a vehicle controller 71 and a motor controller control module 72. Unit 72, along with the on-board charger and DC-DC converter control unit 73, are all electrically connected to the vehicle controller 71. The motor controller control unit 72 is electrically connected to the motor controller drive module 5, and the on-board charger and DC-DC converter control unit 73 is electrically connected to the on-board charger and DC-DC converter drive module 6. The motor controller control unit controls the motor controller drive module, and the on-board charger and DC-DC converter control unit controls the on-board charger and DC-DC converter drive module. Thus, by integrating the electromagnetic compatibility filter 2, bus capacitor 3, power distribution unit 4, motor controller drive module 5, on-board charger and DC-DC converter drive module 6, and main control module 7 within the on-board battery pack 1, some structural components and cooling water circuits can be shared among the components. This improves system volume utilization and power density, reduces the length of high-voltage wiring harnesses, copper busbars, cooling pipes, and power supply lines required by the high-voltage system, and significantly reduces costs.

[0067] Furthermore, since the electromagnetic compatibility filter 2, bus capacitor 3, power distribution unit 4, motor controller drive module 5, on-board charger and DC-DC converter drive module 6 and main control module 7 are all integrated inside the on-board battery pack 1 in this utility model, each component is located inside the power supply end of the on-board battery pack 1, which greatly reduces the transmission distance between each component and the power supply end, reduces transmission loss, and improves efficiency.

[0068] Figure 3 A partial power topology diagram of the all-in-one high-voltage controller provided in this embodiment of the present invention is shown below. Figure 3 The on-board charger and DC-DC converter drive module 6 includes a power factor correction circuit 61, a capacitor-inductor circuit 62, and a DC-DC converter circuit 63, which are connected in sequence.

[0069] in, Figure 3For ease of reference, the power factor correction circuit 61 is referred to as PFC (Power Factor Correction), the capacitor and inductor circuit 62 is referred to as CLLC (Capacitance Inductance Capacitance), and the DC-DC converter circuit 63 is referred to as DCDC (Direct Current-To-Direct Current Converter).

[0070] In use, an external three-phase AC power supply is connected to the multi-in-one high-voltage controller through the charging interface and enters the inductor and three-phase bridge of the power factor correction circuit 61 for power factor correction and three-phase rectification, outputting DC.

[0071] See also Figure 3 The power factor correction circuit 61 is electrically connected to the DC bus support capacitor 611 at its rear end, which is used to stabilize the output voltage and provide input voltage for the next stage capacitor-inductor circuit 62.

[0072] The capacitor-inductor circuit 62 includes a primary circuit and a secondary circuit. Figure 3 In this context, CLLC primary side refers to the primary circuit of a capacitor and an inductor, while CLLC secondary side refers to the secondary circuit of a capacitor and an inductor.

[0073] Both the primary and secondary circuits of the capacitor and inductor circuits are equipped with resonant capacitors, and the leakage inductance and magnetizing inductance of the transformer are used as resonant inductors. Both circuits are equipped with full-bridge switching circuits, forming a symmetrical circuit topology. All switches are fully controllable devices, enabling bidirectional energy transfer.

[0074] Furthermore, the internal switches, inductors, transformers, and other components of the all-in-one high-voltage controller provided in this embodiment of the invention are all electrically connected via circuit boards or copper busbars.

[0075] Therefore, the on-board charger and DC-DC converter drive module 6 achieves bidirectional energy exchange by setting up a capacitor-inductor circuit 62. A single on-board charger and DC-DC converter drive module 6 can simultaneously enable external charging piles to charge the vehicle, the vehicle to charge external loads or other vehicles, and the vehicle to interact with the power grid. This gives the on-board battery pack richer functionality. The scenario of the vehicle charging external loads or other vehicles can be used for camping or roadside assistance. The interaction between the vehicle and the power grid can be used for peak shaving and valley filling, charging during off-peak hours and selling the battery back to the grid during peak hours, thus maximizing the utilization rate of the on-board battery pack.

[0076] However, power factor correction circuits 61 typically suffer from the disadvantages of having a large number of switching devices and large inductors, which increases the overall size and cost of the converter. Therefore, to address this disadvantage, this embodiment of the invention utilizes the power devices of the motor controller drive module 5 as the power switches required by the front-end power factor correction circuit 61, and uses the inductance of the motor as the inductor of the power factor correction circuit 61. Specifically, three changes are required to the original structure:

[0077] 1. Add two switches to motor controller drive module 5;

[0078] 2. Replace the inductor in the power factor correction circuit 61 with the inductor of the motor;

[0079] 3. Add two switches between the three phases of the motor.

[0080] For details, please refer to [link / reference]. Figure 3 The multi-functional high-voltage controller also includes a first switch, a second switch, a third switch 8, and a fourth switch 9.

[0081] The high-voltage bus of the motor controller drive module 5 is electrically connected to the first switch and the second switch respectively. The first switch is electrically connected to the bus of the vehicle battery pack 1, and the second switch is electrically connected to the bus support capacitor 611 of the power factor correction circuit 61. When the motor controller drive module 5 is running, the first switch is closed and the second switch is open. When the motor controller drive module 5 is not running and is in power factor correction mode, the first switch is open and the second switch is closed.

[0082] The inductor in the power factor correction circuit 61 is the inductance of the motor. The three phases of the motor are electrically connected to the third switch 8 and the fourth switch 9 respectively. When the motor is running, both the third switch 8 and the fourth switch 9 are closed. When the motor is not running and is in power factor correction mode, both the third switch 8 and the fourth switch 9 are open.

[0083] Therefore, by setting the high-voltage bus of the motor controller drive module 5 to be electrically connected to the first switch and the second switch respectively, the first switch to be electrically connected to the bus of the vehicle battery pack 1, the second switch to be electrically connected to the bus support capacitor 611 of the power factor correction circuit 61, and by replacing the inductor in the power factor correction circuit 61 with the inductor of the motor, the function of the power factor correction circuit 61 can be realized using existing components on the vehicle, reducing size and cost.

[0084] See also Figure 3 The all-in-one high-voltage controller also includes a transformer, and the inductors of the capacitor-capacitor circuit 62 and the DC-DC converter circuit 63 are all wound around the transformer core 10.

[0085] In this embodiment of the utility model, a magnetic integration design, i.e., a shared transformer core, is adopted. Specifically, the inductance of the capacitor-inductor circuit 62 and the inductance of the DC-DC converter circuit 63 are both wound around the transformer core 10.

[0086] In use, the power factor correction circuit 61 inverts the electrical energy to charge the vehicle battery pack 1 while also achieving high and low voltage isolation. The DC-DC converter circuit 63 uses the power from the external AC charging pile to supply power to the low-voltage load of the vehicle.

[0087] Thus, by winding the inductance of the capacitor-inductor circuit 62 and the inductance of the DC-DC converter circuit 63 around the magnetic core 10 of the transformer, magnetic integration is achieved. This allows the high voltage of the vehicle battery pack 1 to be converted to the low voltage of the DC-DC converter circuit 63 through the same transformer, and bidirectional energy exchange is achieved by sharing the magnetic core 10 of the transformer, which greatly reduces the size and cost.

[0088] Figure 4 A schematic diagram illustrating the implementation effect of the multi-functional high-voltage controller provided in this embodiment of the utility model. See also... Figure 1 and Figure 4 The vehicle controller 71 includes a vehicle dynamic control unit and a vehicle electronic stability system. Figure 4 In this context, the Vehicle Dynamic Control Unit (VDU) is used to refer to the Vehicle Dynamic Control Unit, the Electronic Stability Program (ESP) is used to refer to the Electronic Stability Program, and the Motor Controller Control Unit 72 is used to refer to the MCU.

[0089] In the existing approach, the vehicle dynamics control unit, electronic stability system, vehicle controller, and motor controller all exist independently. Therefore, the transmission links are relatively long. Commands from the motor controller must be transmitted to the motor, then to the wheels, and finally to the wheel speed sensors. These commands then pass through the electronic stability system and the vehicle dynamics control unit to reach the vehicle controller, which in turn transmits them to the motor controller. This results in control delays in the hundreds of milliseconds.

[0090] In this invention, to reduce control delay, the vehicle dynamic control unit and the electronic stability system are integrated into the vehicle controller 71. That is, the vehicle controller 71 includes the vehicle dynamic control unit and the electronic stability system. Furthermore, the vehicle controller 71 and the motor controller control unit 72 are integrated into the main control module 7. Therefore, the vehicle dynamic control unit, the electronic stability system, the vehicle controller 71, and the motor controller control unit 72 are all integrated into the main control module 7. Figure 4 The dotted line in the diagram below integrates the functions of the four components. During control, the wheel speed sensor can directly transmit the data to the main control module 7, thus reducing the control delay to the millisecond level.

[0091] Therefore, the all-in-one high-voltage controller provided by this utility model can integrate the vehicle dynamic control unit, the vehicle electronic stability system and other power / high voltage related functions with the motor controller control unit 72 into the same controller at the control level, which can significantly shorten the control link between the coupled control modules, thereby improving the dynamic control performance and reducing the control delay from hundreds of milliseconds to milliseconds.

[0092] See also Figure 1 The main control module 7 also includes a battery management system 74 and a thermal management system 75. Figure 1 In this document, the Battery Management System 74 is referred to as BMS (Battery Management System), and the Thermal Management System 75 is referred to as TMS (Thermal Management System). The Battery Management System 74 supplies power to the vehicle battery pack 1, while the Thermal Management System 75 monitors and regulates the temperature of various vehicle components to ensure they operate within their optimal temperature range.

[0093] Therefore, the main control module 7 also integrates the battery management system 74 and the thermal management system 75, both of which are related to the high-voltage power domain. This achieves the integration of all systems related to the high-voltage power domain, enabling the all-in-one high-voltage controller to perform various functions related to the high-voltage power domain.

[0094] See also Figure 2The multi-in-one high-voltage controller provided in this embodiment of the utility model also includes a fast charging connector 11, an on-board charger connector 12, a vehicle low-voltage connector 13, a high-voltage AC connector 14, and a low-voltage DC connector 15 installed on the peripheral interface of the vehicle battery pack 1.

[0095] Figure 2 For ease of reference, fast charging connector 11 is referred to as fast charging, on-board charger connector 12 is referred to as OBC (Onboard Charger), high voltage AC connector 14 is referred to as HVAC (High Voltage Alternating Current), and low voltage DC connector 15 is referred to as LVDC (Low Voltage Direct Current).

[0096] The power distribution unit 4 is electrically connected to the fast charging connector 11. The on-board charger and DC-DC converter drive module 6 are electrically connected to the on-board charger connector 12 and the low-voltage DC connector 15, respectively. The main control module 7 is electrically connected to the vehicle low-voltage connector 13. The motor controller drive module 5 is electrically connected to the high-voltage AC connector 14.

[0097] Among them, the fast charging connector 11 and the on-board charger connector 12 are used to charge the on-board battery pack 1 from the outside; the high-voltage AC connector 14 is used to charge the motor from the on-board battery pack 1; and the low-voltage DC connector 15 is used to supply power from the on-board battery pack 1 to the low-voltage system of the whole vehicle.

[0098] Therefore, by installing the fast charging connector 11, the on-board charger connector 12, the vehicle low-voltage connector 13, the high-voltage AC connector 14, and the low-voltage DC connector 15 on the external interface of the vehicle battery pack 1, each connector is led out to the external interface of the vehicle battery pack 1, while the wiring harnesses related to each connector are inside the vehicle battery pack 1. This reduces the complexity and usage of external wiring harnesses, copper busbars, and cooling pipes, thereby reducing raw material costs and assembly costs.

[0099] See also Figure 1 The all-in-one high-voltage controller also includes a high-voltage DC connector 16 that is fixedly installed inside the vehicle battery pack. Figure 1 In the text, the high voltage direct current connector 16 is referred to as HVDC (High Voltage Direct Current), and the power distribution unit 4 is electrically connected to the high voltage direct current connector 16.

[0100] Among them, the high-voltage DC connector 16 is used to supply high-voltage DC power to the vehicle battery pack 1.

[0101] Thus, high-voltage DC power is supplied to the vehicle battery pack 1 by setting the high-voltage DC connector 16.

[0102] See also Figure 1 The all-in-one high-voltage controller also includes an electric heating film connector 17, which is fixedly installed inside the vehicle battery pack. Figure 1 In the text, the electric heating film connector 17 is referred to as PTC (Positive Temperature Coefficient thermistor), and the power distribution unit 4 is electrically connected to the electric heating film connector 17.

[0103] Among them, the electric heating film connector 17 is used to heat the vehicle battery pack 1.

[0104] Thus, heating of the vehicle battery pack 1 is achieved by setting the electric heating film connector 17.

[0105] In another implementation, this utility model embodiment also provides a vehicle, including:

[0106] The vehicle body, the vehicle battery pack, and the multi-in-one high-voltage controller are provided. The multi-in-one high-voltage controller is fixedly installed inside the vehicle battery pack, and the vehicle battery pack is fixedly installed inside the vehicle body. The multi-in-one high-voltage controller is one of the multi-in-one high-voltage controllers provided in any of the above embodiments.

[0107] Therefore, the vehicle provided in this embodiment of the utility model includes a vehicle body, an on-board battery pack, and a multi-functional high-voltage controller. The multi-functional high-voltage controller includes an electromagnetic compatibility filter 2, a bus capacitor 3, a power distribution unit 4, a motor controller drive module 5, an on-board charger and DC-DC converter drive module 6, and a main control module 7, all fixedly installed inside the on-board battery pack 1. The power distribution unit 4 is electrically connected to the electromagnetic compatibility filter 2, the electromagnetic compatibility filter 2 is electrically connected to the bus capacitor 3, and the bus capacitor 3 is electrically connected to the motor controller drive module 5 and the on-board charger and DC-DC converter drive module 6, respectively. The main control module 7 includes a vehicle controller 7. 1. The motor controller control unit 72 and the on-board charger and DC-DC converter control unit 73 are both electrically connected to the vehicle controller 71. The motor controller control unit 72 is electrically connected to the motor controller drive module 5, and the on-board charger and DC-DC converter control unit 73 is electrically connected to the on-board charger and DC-DC converter drive module 6. The motor controller control unit controls the motor controller drive module, and the on-board charger and DC-DC converter control unit controls the on-board charger and DC-DC converter drive module. Therefore, by integrating the electromagnetic compatibility filter 2, bus capacitor 3, power distribution unit 4, motor controller drive module 5, on-board charger and DC-DC converter drive module 6, and main control module 7 all within the on-board battery pack 1, some structural components and cooling water circuits can be shared among the components, improving system volume utilization and power density, reducing the length of high-voltage wiring harnesses, copper busbars, cooling pipes, and power supply lines required by the high-voltage system, and significantly reducing costs.

[0108] Those skilled in the art will understand that the accompanying drawings are merely schematic diagrams of one embodiment, and the modules or processes shown in the drawings are not necessarily essential for implementing this utility model.

[0109] Those skilled in the art will understand that the modules in the apparatus of the embodiments can be distributed in the apparatus of the embodiments as described in the embodiments, or they can be located in one or more devices different from this embodiment with corresponding changes. The modules of the above embodiments can be combined into one module, or they can be further divided into multiple sub-modules.

[0110] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it; although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model.

Claims

1. A multi-in-one high voltage controller, characterized in that, The multi-in-one high-voltage controller comprises: An electromagnetic compatibility filter, a bus capacitor, a power distribution unit, a motor controller driving module, an on-board charger and a DC-DC converter driving module and a master control module fixedly installed inside a vehicle-mounted battery pack; The power distribution unit is electrically connected with the electromagnetic compatibility filter, the electromagnetic compatibility filter is electrically connected with the bus capacitor, and the bus capacitor is respectively electrically connected with the motor controller driving module and the on-board charger and DC-DC converter driving module; The master control module comprises a vehicle controller, a motor controller control unit and an on-board charger and DC-DC converter control unit, the motor controller control unit and the on-board charger and DC-DC converter control unit are electrically connected with the vehicle controller, the motor controller control unit is electrically connected with the motor controller driving module, and the on-board charger and DC-DC converter control unit is electrically connected with the on-board charger and DC-DC converter driving module; The motor controller control unit is used for controlling the motor controller driving module, and the on-board charger and DC-DC converter control unit is used for controlling the on-board charger and DC-DC converter driving module.

2. A multi-in-one high voltage controller as claimed in claim 1, characterized in that, The on-board charger and DC-DC converter driving module comprises a power factor correction circuit, a capacitor-inductor-inductor-capacitor circuit and a DC-DC converter circuit connected in sequence.

3. A multi-in-one high voltage controller as claimed in claim 2, characterized in that, The multi-in-one high-voltage controller further comprises a first switch, a second switch, a third switch and a fourth switch; The high-voltage bus of the motor controller driving module is respectively electrically connected with the first switch and the second switch, the first switch is electrically connected with the bus of the vehicle-mounted battery pack, and the second switch is electrically connected with the DC bus support capacitor of the power factor correction circuit; when the motor controller driving module is running, the first switch is closed and the second switch is opened; when the motor controller driving module is not running and is in a power factor correction mode, the first switch is opened and the second switch is closed. The inductor in the power factor correction circuit is the inductor of a motor, the three phases of the motor are respectively electrically connected with the third switch and the fourth switch; when the motor is running, the third switch and the fourth switch are both closed; when the motor is not running and is in a power factor correction mode, the third switch and the fourth switch are both opened.

4. A multi-in-one high voltage controller as claimed in claim 3, characterized in that, The multi-in-one high-voltage controller further comprises a transformer; The inductor of the capacitor-inductor-inductor-capacitor circuit and the inductor of the DC-DC converter circuit are both wound on the magnetic core of the transformer.

5. A multi-in-one high voltage controller as claimed in claim 1, wherein, The vehicle controller comprises a vehicle dynamic control unit and a vehicle body electronic stability system.

6. A multi-in-one high voltage controller as claimed in claim 1, wherein, The master control module further comprises a battery management system and a thermal management system.

7. A multi-in-one high voltage controller as claimed in claim 1, wherein, The multi-in-one high-voltage controller further comprises a fast charging connector, an on-board charger connector, a vehicle low-voltage connector, a high-voltage AC connector and a low-voltage DC connector installed on the peripheral interface of the vehicle-mounted battery pack. The power distribution unit is electrically connected with the fast charging connector, the vehicle-mounted charger and the DC-DC converter driving module are respectively electrically connected with the vehicle-mounted charger connector and the low-voltage DC connector, the main control module is electrically connected with the whole vehicle low-voltage connector, and the motor controller driving module is electrically connected with the high-voltage AC connector.

8. A multi-in-one high voltage controller as claimed in claim 7, characterized in that, The all-in-one high-voltage controller further comprises a high-voltage DC connector fixedly installed in the interior of the vehicle-mounted battery pack. The power distribution unit is electrically connected with the high-voltage DC connector.

9. A multi-in-one high voltage controller as claimed in claim 1, wherein, The all-in-one high-voltage controller further comprises an electric heating film connector fixedly installed in the interior of the vehicle-mounted battery pack. The power distribution unit is electrically connected with the electric heating film connector.

10. A vehicle characterized by comprising: Comprise: A vehicle body, a vehicle-mounted battery pack and an all-in-one high-voltage controller; The all-in-one high-voltage controller is fixedly installed in the vehicle-mounted battery pack, and the vehicle-mounted battery pack is fixedly installed in the vehicle body, wherein the all-in-one high-voltage controller is an all-in-one high-voltage controller as claimed in any one of claims 1-9.

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