Series hierarchical high-voltage EMC (Electro Magnetic Compatibility) filtering framework of pure electric heavy truck power domain integrated controller

Abstract

The utility model discloses a series hierarchical high-voltage EMC (Electro Magnetic Compatibility) filtering framework of a pure electric heavy truck power domain integrated controller. The utility model discloses a series hierarchical high-voltage EMC filtering framework of a pure electric heavy truck power domain integrated controller. The series hierarchical high-voltage EMC filtering framework comprises a high-voltage bus port; the multiple power modules are connected with the high-voltage bus port in parallel, the power modules are divided into N levels according to the interference noise intensity of the power modules, the multiple power modules are arranged in a graded mode, and each level at least comprises one power module; and each stage of high-voltage filter circuit in the N stages of high-voltage filter circuits is arranged at the front end of each stage of power module in the N stages of power modules in a one-to-one correspondence manner. According to the utility model, the high-voltage filtering measure of the domain integrated controller is more targeted, the filtering effect is improved, and in addition, the complexity of filtering parameter adjustment can be effectively reduced.

Description

Technical Field

[0001] This utility model relates to the field of electromagnetic compatibility technology for new energy vehicle components, and in particular to a series hierarchical high-voltage EMC filtering architecture for a pure electric heavy truck power domain integrated controller. Background Technology

[0002] Given the increasing penetration rate of vehicle electrification, the industry's requirements for the electromagnetic compatibility (EMC) performance of new energy vehicles and their components are also gradually increasing. Based on the different frequency bands of EMC interference, interference signals can generally be divided into high-frequency interference noise and low-frequency interference noise; based on the different modes of interference noise, they are generally divided into common-mode interference noise and differential-mode interference noise. In the design of practical filtering schemes, different filtering measures are selected based on the frequency of the interference source and the interference noise mode. Currently, commonly used filtering measures in the market are divided into "absorption" and "bypass." Magnetic rings or clasps made of nanocrystalline or ferrite magnetic materials can effectively "absorb" interference noise; safety-certified X capacitors and safety-certified Y capacitors, specially designed to utilize the "AC-passing, DC-blocking" characteristic of capacitors, can effectively "bypass" common-mode interference noise and differential-mode interference noise. Therefore, common EMC filtering schemes are all composed of the selection and superposition of the above filtering measures.

[0003] Existing high-voltage EMC filtering measures for all-in-one integrated controllers generally fall into two main categories. One is a centralized filtering design scheme, such as... Figure 2 As shown; another is a distributed filtering design method, such as... Figure 3 As shown. Centralized filtering scheme refers to applying all high-voltage filtering measures to the input port of the busbar, ignoring the suppression measures at the interference sources of each power module, and concentrating the measures at the break point to suppress the transmission of interference signals; distributed filtering scheme refers to arranging independent EMC filtering measures at the busbar input of different power modules, ignoring the application of EMC filtering measures at the high-voltage busbar port of the whole machine.

[0004] Centralized filtering designs neglect filtering measures at the interference sources of each power module, concentrating all filtering measures at the bus input port. This approach cannot suppress spatial coupling interference between different power modules or the conduction of interference noise between different power units, potentially causing malfunctions in individual functional units and affecting module characteristics. Concentrating filtering measures at the port results in larger filter sizes, crowded port layouts, and increased likelihood of coupling between interference noise. Distributed filtering designs focus on suppressing interference noise from each power module, neglecting the application of filtering measures at the bus port. When interference noise is spatially coupled at the bus port, it can radiate to the external end of the all-in-one integrated controller through conduction, affecting the overall vehicle EMC characteristics. Summary of the Invention

[0005] Based on this, it is necessary to provide a series hierarchical high-voltage EMC filtering architecture for the power domain integrated controller of pure electric heavy trucks to address the above-mentioned technical problems. This makes the high-voltage filtering measures of the power domain integrated controller more targeted, improves the filtering effect, and effectively reduces the complexity of adjusting the filtering parameters.

[0006] Firstly, a series-level high-voltage EMC filtering architecture for a pure electric heavy-duty truck power domain integrated controller is provided, including:

[0007] High-voltage busbar port;

[0008] Multiple power modules are connected in parallel to the high-voltage bus port. The multiple power modules are divided into N levels according to their own interference noise intensity, and the multiple power modules are arranged in a hierarchical manner, with each level including at least one power module.

[0009] The N-stage high-voltage filter circuit, wherein each stage of the high-voltage filter circuit is correspondingly located at the front end of each stage of the power module in the N-stage power module.

[0010] Furthermore, the N-stage power module includes a first-stage power module, a second-stage power module, and a third-stage power module. Correspondingly, the N-stage high-voltage filter circuit includes a first-stage high-voltage filter circuit, a second-stage high-voltage filter circuit, and a third-stage high-voltage filter circuit, wherein:

[0011] The first-stage high-voltage filter circuit is disposed between the high-voltage bus port and the first-stage power module, the second-stage high-voltage filter circuit is disposed between the first-stage power module and the second-stage power module, and the third-stage high-voltage filter circuit is disposed between the second-stage power module and the third-stage power module.

[0012] Furthermore, the first-stage power module includes a DCAC module, the second-stage power module includes a DC-DC module and other power modules, and the third-stage power module includes an MCU module.

[0013] Furthermore, the DCAC module includes a first DCAC module and a second DCAC module, and the MCU module includes a first MCU module and a second MCU module.

[0014] Furthermore, each stage of the N-stage high-voltage filter circuit consists of a Y capacitor, an X capacitor, and a magnetic ring.

[0015] Furthermore, the Y capacitor includes a first Y capacitor and a second Y capacitor, which are connected in series between the high-voltage bus ports. The X capacitor is connected between the high-voltage bus ports and is connected in parallel with the first Y capacitor and the second Y capacitor. The magnetic ring is disposed at the rear end of the X capacitor.

[0016] Furthermore, each stage of the high-voltage filter circuit has a grounding point for the first Y capacitor and the second Y capacitor, and the grounding point is connected to the housing of the power domain integrated controller.

[0017] Furthermore, the series hierarchical high-voltage EMC filter architecture of the pure electric heavy-duty truck power domain integrated controller is used for electric heavy-duty trucks.

[0018] In a second aspect, a vehicle is provided, comprising: a series hierarchical high-voltage EMC filter architecture for a pure electric heavy-duty truck power domain integrated controller as described in the first aspect above.

[0019] Furthermore, the vehicle is an electric heavy-duty truck.

[0020] The embodiments of this utility model employ a series-level filtering design architecture, which, compared to a centralized filtering design, configures different levels of filtering measures according to the strength of interference noise. This effectively suppresses the transmission effects of different interference noises, ensuring the EMC characteristics of the power domain all-in-one assembly. Connecting filter units in series between high-voltage buses from different interference sources suppresses conducted interference between these sources, improving the anti-interference capability of each functional unit and ensuring the anti-interference capability of each module within the power domain all-in-one assembly. The reasonable series connection of high-voltage bus filter units avoids the problem of high-voltage bus filter unit accumulation at the ports, optimizing the controller all-in-one assembly. The assembly's structural layout places the filter modules hierarchically at the high-voltage bus ports, which can suppress interference noise coupling and allow the copper busbars at the ports to conduct the signal to the power domain multi-in-one controller through the high-voltage positive and negative buses. This improves the anti-interference level of the power domain multi-in-one controller assembly. By classifying interference sources according to their intensity and level and using the same filtering measures in parallel, the reusability of the filter units is improved, the construction layout space is reduced, and the number of filter units used is reduced, thus achieving cost reduction in the design. Attached Figure Description

[0021] Other features, objects, and advantages of this invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0022] Figure 1 A structural block diagram of a series hierarchical high-voltage EMC filter architecture for a pure electric heavy-duty truck power domain integrated controller provided in this embodiment of the utility model;

[0023] Figure 2 This is a schematic diagram of a high-voltage EMC filtering architecture for a power domain integrated controller in related technologies;

[0024] Figure 3 This is a schematic diagram of a high-voltage EMC filtering architecture for another power domain integrated controller in related technologies. Detailed Implementation

[0025] The present invention will now be described in further detail with reference to the embodiments and accompanying drawings. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the invention. Furthermore, it should be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings.

[0026] It should be noted that, where there is no conflict, the embodiments and features of the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0027] The following describes in detail, with reference to the accompanying drawings, the series hierarchical high-voltage EMC filter architecture of the pure electric heavy truck power domain integrated controller according to an embodiment of the present invention.

[0028] Figure 1 This is a structural block diagram of a series-level high-voltage EMC filter architecture for a pure electric heavy-duty truck power domain integrated controller according to an embodiment of the present invention. Figure 1 As shown, the series-level high-voltage EMC filtering architecture of the pure electric heavy-duty truck power domain integrated controller according to an embodiment of this utility model includes: a high-voltage bus port 110, multiple power modules, and an N-stage high-voltage filtering circuit, wherein:

[0029] Multiple power modules are connected in parallel to the high-voltage bus port 110. These power modules are divided into N levels based on their interference noise intensity, and are arranged in a hierarchical manner, with each level including at least one power module. Each high-voltage filter circuit in the N levels is correspondingly located at the front end of each power module in the N-level power module group.

[0030] As a concrete example, combined Figure 1 As shown, the N-stage power module includes a first-stage power module 121, a second-stage power module 122, and a third-stage power module 123. Correspondingly, the N-stage high-voltage filter circuit includes a first-stage high-voltage filter circuit 131, a second-stage high-voltage filter circuit 132, and a third-stage high-voltage filter circuit 133, wherein:

[0031] The first-stage high-voltage filter circuit 131 is disposed between the high-voltage bus port 110 and the first-stage power module 121, the second-stage high-voltage filter circuit 132 is disposed between the first-stage power module 121 and the second-stage power module 122, and the third-stage high-voltage filter circuit 133 is disposed between the second-stage power module 122 and the third-stage power module 123.

[0032] In a specific example, the first-stage power module 121 includes a DCAC module, and the second-stage power module 122 includes a DCCDC module (i.e., Figure 1 (DC-CDC) and other power modules (i.e. Figure 1 (others in the same module), the third-level power module 123 includes an MCU module.

[0033] Combination Figure 1 As shown, in a specific application, the DCAC module includes a first DCAC module DCAC1 and a second DCAC module DCAC2, and the MCU module includes a first MCU module MCU1 and a second MCU module MCU2.

[0034] Each stage of the N-stage high-voltage filter circuit consists of a Y capacitor, an X capacitor, and a magnetic ring.

[0035] Specifically, the Y capacitor includes a first Y capacitor and a second Y capacitor, which are connected in series between the high-voltage bus ports. The X capacitor is connected between the high-voltage bus ports and in parallel with the first and second Y capacitors. The magnetic ring is disposed at the rear end of the X capacitor. For example, taking the first-stage high-voltage filter circuit 131 as an example, combined with... Figure 1 As shown, the first-stage high-voltage filter circuit 131 includes a first Y capacitor CY19 and a second Y capacitor CY20. The first Y capacitor CY19 and the second Y capacitor CY20 are connected in series between the high-voltage bus ports 110. The X capacitor CX10 is connected between the high-voltage bus ports 110 and is connected in parallel with the first Y capacitor CY19 and the second Y capacitor CY20. The magnetic ring L10 is disposed at the rear end of the X capacitor CX10.

[0036] In each stage of the high-voltage filter circuit, the first Y capacitor and the second Y capacitor are provided with grounding points, which are connected to the housing of the power domain integrated controller. Taking the first-stage high-voltage filter circuit 131 as an example, combined with... Figure 1 As shown, there is a grounding point between the first Y capacitor CY19 and the second Y capacitor CY20, and the connection point FG is the housing of the power domain integrated controller.

[0037] The series-level high-voltage EMC filtering architecture of the pure electric heavy-duty truck power domain integrated controller of this utility model embodiment is typically used in electric heavy-duty trucks. That is, the series-level high-voltage EMC filtering design architecture for the new energy power domain all-in-one integrated controller can suppress interference noise in stages according to the differences in interference noise intensity between power modules; the filtering parameters of each level are independent and can be set and adjusted separately, making the high-voltage filtering measures of the all-in-one power domain more targeted and reducing the complexity of filtering parameter adjustment.

[0038] Specifically, combined Figure 1 As shown, the DCAC1 module, DCAC2 module, DCDC module, MCU1 module, MCU2 module, and other power modules are the functional units of the power domain all-in-one integrated controller. The number and connection order of different power modules can be adjusted according to actual usage needs. All power modules draw power from the high-voltage bus port, and the current from each power source flows from the positive terminal to the negative terminal of the high-voltage bus port. The power modules are connected in parallel relative to the high-voltage bus port. The arrangement of the power modules can be designed according to their power ratings and the intensity of interference they generate. In this example, the MCU has a power rating of over 120kW and is the largest source of interference in the entire power domain all-in-one controller. The DCDC module has a complex circuit with multiple variations, resulting in relatively high interference intensity and making it the second largest source of interference in the controller. The DCAC module, due to its low power and simple circuit architecture, has the weakest interference capability.

[0039] Y capacitor CY19, Y capacitor CY20, X capacitor CX10 and magnetic ring L10 constitute the first-stage high-voltage filter circuit 131; Y capacitor CY21, Y capacitor CY22, X capacitor CX11 and magnetic ring L11 constitute the second-stage high-voltage filter circuit 132; Y capacitor CY23, Y capacitor CY24, X capacitor CX13 and magnetic ring L13 constitute the third-stage high-voltage filter circuit 133; FG is the grounding network of the high-voltage filter unit, connected to the housing of the power domain all-in-one controller.

[0040] In this example, the functional units are arranged hierarchically based on the differences in power modules and interference noise intensity; the arrangement architecture of different power modules is as follows: Figure 1As shown. The DCAC module with weaker interference is positioned after the first-stage high-voltage filter circuit 131. High-voltage power passes through the first-stage high-voltage filter circuit 131 to power the DCAC module. Similarly, interference noise generated by the DCAC module is suppressed and absorbed by the first-stage high-voltage filter circuit 131 before flowing out of the high-voltage bus port 110. The DC-DC module with stronger interference is positioned between the second-stage high-voltage filter circuit 132 and the third-stage high-voltage filter circuit 133. High-voltage power passes through the first-stage high-voltage filter circuit 131 and the second-stage high-voltage filter circuit 132 before powering the DC-DC module. Similarly, interference noise generated by the DC-DC module is suppressed and absorbed by the first-stage high-voltage filter circuit 131 and the second-stage high-voltage filter circuit 132 before flowing out of the high-voltage bus port 110. The MCU module with the strongest interference is located after the third-stage high-voltage filter circuit 133. High-voltage power flows through the first-stage high-voltage filter circuit 131, the second-stage high-voltage filter circuit 132, and the third-stage high-voltage filter circuit 133 in sequence before powering the MCU module. Similarly, the interference noise generated by the MCU module will be suppressed and absorbed by the first-stage high-voltage filter circuit 131, the second-stage high-voltage filter circuit 132, and the third-stage high-voltage filter circuit 133 in sequence before flowing out of the high-voltage bus port 110.

[0041] The analysis focuses on the conduction path of interference noise. The interference noise generated by MCU1 and MCU2 modules is suppressed sequentially by the third-stage high-voltage filter circuit 133, the second-stage high-voltage filter circuit 132, and the first-stage high-voltage filter circuit 131, maximizing the suppression of interference noise generated by the MCUs from being conducted to the high-voltage bus port 110 via the positive and negative high-voltage buses. The interference noise generated by the DC-DC module is suppressed sequentially by the second-stage high-voltage filter circuit 132 and the first-stage high-voltage filter circuit 131, resulting in attenuation of the intensity of interference noise generated by DC-DC signals conducted to the high-voltage bus port 110 via the high-voltage bus. The interference noise generated by the DC-AC module is suppressed by the first-stage filter circuit 131. Since the interference intensity of the DC-AC module is relatively weak, after suppression and absorption by the first-stage filter circuit 131, the intensity of the interference noise conducted to the high-voltage port 110 via the high-voltage bus will be further attenuated. Different levels of filtering are used depending on the intensity of the interference noise source. The MCU with the strongest interference noise intensity uses the highest level of filtering.

[0042] Depend on Figure 1As can be seen from the filtering architecture, the bus cables between different power modules are all separated by filtering units. The high-voltage bus between the DCAC function and the DCDC function is isolated by the second-stage high-voltage filter circuit 132; the high-voltage bus between the DCDC function and the MCU function is isolated by the third-stage high-voltage filter circuit 133; the high-voltage bus between the MCU function unit and the DCAC function unit is isolated by the second-stage high-voltage filter circuit 132 and the third-stage high-voltage filter circuit 133. This embodiment of the invention employs an architecture that isolates the bus connections between interference source modules with different interference intensities, effectively suppressing the conduction of interference noise from different interference sources through the high-voltage bus. This effectively improves the conduction anti-interference capability of each power module.

[0043] This analysis focuses on the spatial coupling of interference noise within the cavity of the power domain all-in-one controller. Because modules with different interference levels employ a series-based, step-by-step filtering architecture, it facilitates the physical isolation of the power modules within the cavity structure. This effectively suppresses the spatial coupling effect of interference noise from different sources, improving the anti-interference capability of the power domain all-in-one controller.

[0044] According to the series-level high-voltage EMC filtering architecture of the pure electric heavy-duty truck power domain integrated controller of this utility model embodiment, compared with the centralized filtering design, the series-level filtering design architecture configures different levels of filtering measures according to the strength of interference noise, which can effectively suppress the conduction effect of different interference noises, ensure the EMC characteristics of the power domain all-in-one assembly, and suppress the conducted interference between different interference sources by connecting the filtering units in series between the high-voltage buses of different interference sources, improve the anti-interference capability of each functional unit, and ensure the anti-interference capability of each module inside the power domain all-in-one assembly. The high-voltage bus filtering units are reasonably arranged in series to avoid the high-voltage bus filtering units at the port. To address the issue of noise accumulation, the structural layout of the all-in-one controller assembly was optimized. Filter modules were placed hierarchically at the high-voltage bus ports, suppressing interference noise coupling. The resulting copper busbars then conducted the signal through the high-voltage positive and negative buses to the power domain all-in-one controller, improving its anti-interference level. By classifying interference sources according to their intensity and level and using the same filtering measures in parallel, the reusability of the filter units was improved, reducing the required layout space. This also reduced the number of filter units used, achieving cost reduction in the design.

[0045] In one embodiment, a vehicle is provided, including a series-level high-voltage EMC filtering architecture for a pure electric heavy-duty truck power domain integrated controller according to one embodiment described above. The vehicle is, for example, an electric heavy-duty truck. Compared to a centralized filtering design, the series-level filtering architecture of this vehicle, configured with different levels of filtering measures according to the strength of interference noise, can effectively suppress the transmission effects of different interference noises, ensuring the EMC characteristics of the integrated power domain assembly. By connecting filtering units in series between high-voltage buses of different interference sources, conducted interference between different interference sources can be suppressed, improving the anti-interference capability of each functional unit and ensuring the anti-interference capability of each module within the integrated power domain. The high-voltage bus filtering units are rationally arranged in series to avoid the problem of high-voltage bus filtering units accumulating at the ports, optimizing the control... The structural layout of the all-in-one controller assembly places the filter modules in layers at the high-voltage bus ports, which can suppress interference noise coupling and obtain the port copper bus, which then conducts the power domain all-in-one controller through the high-voltage positive and negative buses, improving the anti-interference level of the power domain all-in-one controller assembly. According to the noise interference intensity and level, the interference sources are classified and connected in parallel with the same filtering measures, which improves the reusability of the filter units, reduces the construction layout space, and reduces the number of filter units used, thereby achieving design cost reduction.

[0046] Furthermore, other components and functions of the vehicle according to the embodiments of this utility model are known to those skilled in the art and will not be described in detail here.

[0047] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0048] The above embodiments only illustrate several implementation methods of this utility model, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.

Claims

1. A series hierarchical high voltage EMC filter architecture for a pure electric heavy-duty truck power domain integrated controller, characterized in that, Comprising: a high-voltage bus port; a plurality of power modules connected in parallel with the high-voltage bus port, the plurality of power modules being divided into N levels according to their interference noise intensity, and the plurality of power modules being arranged in levels, each level including at least one power module; N-level high-voltage filter circuits, each of the N-level high-voltage filter circuits being arranged at the front end of each of the N-level power modules one-to-one.

2. The series staged high voltage EMC filter architecture of the pure electric heavy-duty truck power domain integrated controller according to claim 1, characterized in that, The N-level power modules include a first-level power module, a second-level power module, and a third-level power module, and correspondingly, the N-level high-voltage filter circuits include a first-level high-voltage filter circuit, a second-level high-voltage filter circuit, and a third-level high-voltage filter circuit, wherein: The first-level high-voltage filter circuit is arranged between the high-voltage bus port and the first-level power module, the second-level high-voltage filter circuit is arranged between the first-level power module and the second-level power module, and the third-level high-voltage filter circuit is arranged between the second-level power module and the third-level power module. 3.The series staged high voltage EMC filter architecture of the pure electric heavy-duty truck power domain integrated controller according to claim 2, characterized in that, The first-level power module includes a DCAC module, the second-level power module includes a DCDC module and other power modules, and the third-level power module includes an MCU module.

4. The series staged high voltage EMC filter architecture of the pure electric heavy-duty truck power domain integrated controller according to claim 3, characterized in that, The DCAC module includes a first DCAC module and a second DCAC module, and the MCU module includes a first MCU module and a second MCU module.

5. The series staged high voltage EMC filter architecture of the pure electric heavy-duty truck power domain integrated controller according to any one of claims 1-4, characterized in that, Each of the N-level high-voltage filter circuits is composed of a Y capacitor, an X capacitor, and a magnetic ring.

6. The series staged high voltage EMC filter architecture of the pure electric heavy-duty truck power domain integrated controller according to claim 5, characterized in that, The Y capacitor includes a first Y capacitor and a second Y capacitor, the first Y capacitor and the second Y capacitor are connected in series between the high-voltage bus ports, the X capacitor is connected between the high-voltage bus ports and in parallel with the first Y capacitor and the second Y capacitor, and the magnetic ring is arranged at the rear end of the X capacitor.

7. The series staged high voltage EMC filter architecture of the pure electric heavy-duty truck power domain integrated controller according to claim 6, characterized in that, The first Y capacitor and the second Y capacitor in each of the high-voltage filter circuits are provided with grounding points connected to the shell of the power domain integrated controller.

8. The series staged high voltage EMC filter architecture of the pure electric heavy-duty truck power domain integrated controller according to claim 1, characterized in that, The power domain integrated controller is used for an electric heavy truck.

9. A vehicle characterized by comprising: Comprising: The series hierarchical high-voltage EMC filter architecture of the pure electric heavy truck power domain integrated controller according to any one of claims 1-8.

10. The vehicle of claim 9, wherein, The vehicle is an electric heavy truck.

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