Motor controller and electric driving system
By introducing a parasitic capacitance structure into the motor controller to absorb voltage spikes, the heat problem caused by the buffer circuit is solved, resulting in higher voltage safety margin and system reliability, while reducing heat and cost.
Patent Information
- Application Number
- CN202423079828.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-12
- Publication Date
- 2026-01-09
- Estimated Expiration
- 2034-12-12
AI Technical Summary
Existing technologies in motor controllers introduce buffer circuits between the DC positive and DC negative terminals or between current conversion bridge arms to achieve smooth voltage and current transitions, resulting in additional heat generation, deteriorating the controller's thermal environment, shortening component lifespan, and reducing system reliability.
The parasitic capacitance structure is adopted, which forms a parasitic capacitance by setting an insulating structure between the conductive structures of the power device. This absorbs voltage spikes during the switching process, improves the voltage safety margin, and eliminates the need for a buffer circuit, thus avoiding the generation of additional heat by passive components.
It improves the thermal environment of the motor controller, extends the life of electronic components, enhances system reliability and electromagnetic interference suppression capabilities, and reduces material and design costs.
Smart Images
Figure CN223785979U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of motor controller technology, and more specifically, to a motor controller and an electric drive system. Background Technology
[0002] The rise of new energy vehicles is a direct result of increased global environmental awareness and the escalating energy crisis. As the core component of electric vehicles, the electric drive system directly impacts a vehicle's energy efficiency, safety, and stability. The motor controller, as the heart of the electric drive system, not only bears the heavy responsibility of power conversion and control but also involves interdisciplinary technologies from multiple fields such as electromechanical engineering, electronics, heat transfer, fluid mechanics, electromagnetics, and simulation, making it a focal point for domestic and international automakers, academic research institutions, and scientific research organizations.
[0003] With the increasing energy efficiency of new energy vehicle systems, the nominal voltage of power batteries is constantly rising, leading to a corresponding increase in the input voltage of the motor controller. This change compresses the voltage and thermal safety margins of power devices, posing a challenge to the stable operation of the controller. To cope with high voltage and high temperature environments, the traditional approach is to introduce a buffer circuit between the DC positive and DC negative terminals or between the current conversion bridge arms to achieve a smooth transition between voltage and current. However, the buffer circuit mainly consists of components such as capacitors, resistors, and fast recovery diodes. The additional heat generated by the buffer circuit during operation can worsen the thermal environment of the controller, shorten the lifespan of other components, and reduce system reliability. Utility Model Content
[0004] The main objective of this invention is to provide a motor controller and electric drive system that can solve the problem that when the existing technology uses a buffer circuit between the DC positive and DC negative poles or between the current conversion bridge arms to achieve a smooth transition of voltage and current, the additional heat generated by the buffer circuit during operation will deteriorate the thermal environment of the controller, leading to a shortened lifespan of other components and a reduced system reliability.
[0005] To achieve the above objectives, according to one aspect of the present invention, a motor controller is provided, comprising: a power device including a first electrode and a second electrode; a capacitor module including a first conductive structure, a second conductive structure and a first insulating structure, wherein the first conductive structure is used to electrically connect to the positive or negative terminal of a power supply, the first insulating structure is disposed between the first conductive structure and the second conductive structure, the first electrode is electrically connected to the first conductive structure, and the second electrode is electrically connected to the second conductive structure.
[0006] Furthermore, the first conductive structure, the first insulating structure, and the second conductive structure are stacked sequentially.
[0007] Furthermore, when projecting along the overlapping direction of the first conductive structure, the first insulating structure, and the second conductive structure, the projections of both the first conductive structure and the second conductive structure fall within the projection area of the first insulating structure.
[0008] Furthermore, the motor controller also includes a second insulation structure, and there are two power devices and two capacitor modules. The two power devices and two capacitor modules are arranged in a one-to-one correspondence. The two capacitor modules are stacked, and the second conductive structures of the two capacitor modules are arranged adjacent to each other. The second insulation structure is arranged between the two second conductive structures.
[0009] Furthermore, there are two power devices and two capacitor modules. The two power devices share a second electrode, and the two capacitor modules share a second conductive structure. Along the first direction, two first insulating structures are arranged opposite each other on opposite sides of the second conductive structure. The two first conductive structures and the two first insulating structures are arranged in a one-to-one correspondence. The first conductive structure is located on the side of the corresponding first insulating structure that is away from the second conductive structure.
[0010] Furthermore, the motor controller also includes a third conductive structure and a third insulating structure. Both the third conductive structure and the third insulating structure are disposed on the side of the first conductive structure away from the first insulating structure. The third insulating structure is located between the first conductive structure and the third conductive structure. One of the first conductive structure and the third conductive structure is connected to the positive terminal of the power supply, and the other of the first conductive structure and the third conductive structure is connected to the negative terminal of the power supply.
[0011] Furthermore, the first conductive structure, the third insulating structure, and the third conductive structure are stacked sequentially, and projected along the stacking direction of the three structures. The projections of the first conductive structure and the third conductive structure both fall within the projection area of the third insulating structure.
[0012] Furthermore, both the first and third insulating structures are made of insulating materials with a dielectric constant ranging from 5 to 10.
[0013] Furthermore, the first conductive structure, the second conductive structure, and the third conductive structure all use copper foil or aluminum foil.
[0014] According to another aspect of the present invention, an electric drive system is provided, comprising: a motor; and the motor controller described above.
[0015] The present invention employs a power device and a capacitor module. The capacitor module includes a first conductive structure, a second conductive structure, and a first insulating structure. By connecting the first conductive structure to the first electrode of the power device and the second conductive structure to the second electrode of the power device, and by placing the first insulating structure between the first and second conductive structures, a parasitic capacitance can be formed. On the one hand, this can absorb voltage spikes generated during switching, improving the voltage safety margin of the power device. On the other hand, this arrangement eliminates the need for a buffer circuit, avoiding the problem of passive components (such as resistors and capacitors) generating additional heat during operation. This improves the thermal environment of the motor controller, helps extend the lifespan of electronic components, and ultimately enhances the reliability of the system. Attached Figure Description
[0016] The accompanying drawings, which form part of this specification, are used to provide a further understanding of this utility model. The illustrative embodiments and descriptions of this utility model are used to explain this utility model and do not constitute an undue limitation thereof.
[0017] In the picture:
[0018] Figure 1 A schematic diagram of the structure of a motor controller according to an embodiment of the present invention is shown.
[0019] The above figures include the following reference numerals:
[0020] 10. Power device; 11. First electrode; 12. Second electrode; 20. Capacitor module; 21. First conductive structure; 22. Second conductive structure; 23. First insulating structure; 30. Second insulating structure; 40. Third conductive structure; 50. Third insulating structure. Detailed Implementation
[0021] It should be noted that, where there is no conflict, the embodiments and features in the embodiments of this utility model can be combined with each other. The present utility model will now be described in detail with reference to the accompanying drawings and embodiments.
[0022] Currently, with the increasing efficiency of drive systems in new energy vehicles, the input voltage of motor controllers is becoming higher and higher, compressing the voltage and thermal safety margins of power devices. This necessitates the installation of buffer circuits between the DC positive and negative terminals or across the power devices. However, high-voltage buffer circuit components are expensive, increasing material costs. Furthermore, the installation of buffer circuits also complicates structural design, further increasing design costs.
[0023] like Figure 1As shown, this utility model provides a motor controller, which includes: a power device 10, including a first electrode 11 and a second electrode 12; a capacitor module 20, including a first conductive structure 21, a second conductive structure 22 and a first insulating structure 23. The first conductive structure 21 is used to electrically connect to the positive or negative terminal of the power supply, and the first insulating structure 23 is disposed between the first conductive structure 21 and the second conductive structure 22. The first electrode 11 is electrically connected to the first conductive structure 21, and the second electrode 12 is electrically connected to the second conductive structure 22.
[0024] In this embodiment, a parasitic capacitance is formed by connecting the first conductive structure 21 to the first electrode 11 of the power device 10, connecting the second conductive structure 22 to the second electrode 12 of the power device 10, and providing a first insulating structure 23 between the first conductive structure 21 and the second conductive structure 22. By forming a capacitor across the power device 10, on the one hand, voltage spikes generated during switching can be absorbed, improving the voltage safety margin of the power device 10; on the other hand, this arrangement eliminates the need for a buffer circuit and expensive buffer components, thus reducing the number of devices, simplifying the system structure, and lowering material costs. Furthermore, it avoids the problem of passive components (such as resistors) generating additional heat during operation, thereby improving the thermal environment of the motor controller, extending the lifespan of electronic components, and ultimately improving system reliability. Simultaneously, the parasitic capacitance acts as a filter, absorbing high-frequency noise and reducing electromagnetic interference (EMI) of the motor controller.
[0025] It should be noted that the size of the parasitic capacitance formed above is determined by the dielectric constant and thickness of the first insulating structure 23 and the overlapping area of the first conductive structure 21 and the second conductive structure 22.
[0026] like Figure 1 As shown, in one embodiment of the present invention, the first conductive structure 21, the first insulating structure 23, and the second conductive structure 22 are stacked sequentially.
[0027] In this embodiment, the first conductive structure 21, the first insulating structure 23, and the second conductive structure 22 are stacked sequentially. This stacked structure can not only realize the construction of capacitors in a limited physical space, but also avoid the problem of traditional capacitors occupying extra space.
[0028] like Figure 1 As shown, in one embodiment of the present invention, projections are made along the stacking direction of the first conductive structure 21, the first insulating structure 23, and the second conductive structure 22, and the projections of the first conductive structure 21 and the second conductive structure 22 both fall within the projection area of the first insulating structure 23.
[0029] The above settings ensure that the formed capacitors have a large effective overlap area, thereby achieving a higher capacitance value, and also ensure sufficient electrical isolation between the first conductive structure 21 and the second conductive structure 22, preventing short circuits caused by direct contact between the first conductive structure 21 and the second conductive structure 22.
[0030] like Figure 1 As shown, in one embodiment of the present invention, the motor controller further includes a second insulating structure 30. There are two power devices 10 and two capacitor modules 20. The two power devices 10 and the two capacitor modules 20 are arranged in a one-to-one correspondence. The two capacitor modules 20 are stacked, and the second conductive structures 22 of the two capacitor modules 20 are arranged adjacent to each other. The second insulating structure 30 is disposed between the two second conductive structures 22.
[0031] In this embodiment, the arrangement of two capacitor modules 20, compared to a single capacitor module 20, provides greater buffering and energy storage capacity. Under high-speed switching operation, it can more effectively absorb voltage or current transients, protecting the power device 10 from voltage spikes. Simultaneously, it provides additional energy support when the power supply is unstable, enhancing the system's stability and reliability. The heat generated by each power device 10 can be directly dissipated to the surrounding environment through the adjacent capacitor modules 20 and the first insulation structure 23, preventing heat accumulation and improving the overall system's heat dissipation efficiency and thermal stability. The stacked arrangement of the two capacitor modules 20 enables efficient capacitor layout within a limited space. The two adjacent second conductive structures 22, isolated by the second insulation structure 30, ensure electrical isolation between them, increasing the system's safety margin and preventing electrical faults such as short circuits.
[0032] like Figure 1 As shown, in one embodiment of the present invention, there are two power devices 10 and two capacitor modules 20. The two power devices 10 share a second electrode 12, and the two capacitor modules 20 share a second conductive structure 22. Along the first direction, two first insulating structures 23 are arranged opposite to each other on opposite sides of the second conductive structure 22. Two first conductive structures 21 are arranged in a one-to-one correspondence with two first insulating structures 23. The first conductive structure 21 is located on the side of the corresponding first insulating structure 23 that is away from the second conductive structure 22.
[0033] In this embodiment, the first direction refers to Figure 1The stacking direction of the two capacitor modules 20. The two power devices 10 share a second electrode 12, and the two capacitor modules 20 share a second conductive structure 22. On the one hand, this reduces the number of second electrodes 12 and second conductive structures 22, thereby reducing material costs. On the other hand, it also reduces the required space, enabling the motor controller to achieve higher integration within a limited physical size, which helps to miniaturize and compact the design of the motor controller.
[0034] like Figure 1 As shown, in one embodiment of the present invention, the motor controller further includes a third conductive structure 40 and a third insulating structure 50. The third conductive structure 40 and the third insulating structure 50 are both disposed on the side of the first conductive structure 21 away from the first insulating structure 23. The third insulating structure 50 is located between the first conductive structure 21 and the third conductive structure 40. One of the first conductive structure 21 and the third conductive structure 40 is connected to the positive terminal of the power supply, and the other of the first conductive structure 21 and the third conductive structure 40 is connected to the negative terminal of the power supply.
[0035] In this embodiment, the arrangement of the third conductive structure 40 and the third insulating structure 50 enables the motor controller to form more capacitors. By increasing the number of capacitors, on the one hand, the transient voltage absorption capability of the motor controller can be improved, enhancing the reliability of the system; on the other hand, multiple capacitors can more effectively smooth the current and reduce current fluctuations. Simultaneously, increasing the number of capacitors helps reduce electromagnetic interference to external devices. The arrangement of the third insulating structure 50 ensures electrical isolation between the first conductive structure 21 and the third conductive structure 40, preventing short circuits caused by direct contact between them.
[0036] like Figure 1 As shown, in one embodiment of the present invention, the first conductive structure 21, the third insulating structure 50 and the third conductive structure 40 are stacked sequentially. When projected along the stacking direction of the first conductive structure 21, the third insulating structure 50 and the third conductive structure 40, the projections of the first conductive structure 21 and the third conductive structure 40 both fall within the projection area of the third insulating structure 50.
[0037] The above settings ensure that the formed capacitors have a large effective overlap area, thereby achieving a higher capacitance value, and also ensure sufficient electrical isolation between the first conductive structure 21 and the third conductive structure 40, preventing short circuits caused by direct contact between the first conductive structure 21 and the third conductive structure 40.
[0038] In one embodiment of this utility model, both the first insulating structure 23 and the third insulating structure 50 are made of insulating materials with a dielectric constant ranging from 5 to 10.
[0039] The above settings can enhance electrical isolation and reduce the risk of short circuits.
[0040] In one embodiment of this utility model, the first conductive structure 21, the second conductive structure 22, and the third conductive structure 40 are all made of copper foil or aluminum foil.
[0041] In one embodiment, the capacitor module 20 can be implemented using a printed circuit board (PCB). This means that it can be specifically implemented using PCB design and manufacturing technology. Specifically, the first conductive structure 21, the second conductive structure 22, and the third conductive structure 40 (usually made of copper foil or aluminum foil) can be integrated as part of the PCB by embedding metal foil in the laminate or laying a metal layer on the PCB surface. The first insulating structure 23 and the third insulating structure 50 can be selected from laminate materials with suitable dielectric constants (such as FR-4 epoxy fiberglass board, PP board, or other composite materials) and placed between the conductive structures as dielectric layers during the PCB manufacturing process.
[0042] According to another aspect of the present invention, an electric drive system is provided, comprising: a motor; and the aforementioned motor controller.
[0043] In this embodiment, the motor controller of the electric drive system has all the technical solutions and effects of the above-mentioned motor control, which will not be repeated here.
[0044] From the above description, it can be seen that the above embodiments of this utility model achieve the following technical effects: A power device and a capacitor module are provided, wherein the capacitor module includes a first conductive structure, a second conductive structure, and a first insulating structure. By connecting the first conductive structure to the first electrode of the power device, and the second conductive structure to the second electrode of the power device, and setting the first insulating structure between the first and second conductive structures, a parasitic capacitance can be formed. On the one hand, this can absorb voltage spikes generated during switching, improving the voltage safety margin of the power device. On the other hand, through the above arrangement, there is no need to set a buffer circuit, which can avoid the problem of passive components (such as resistors, capacitors, etc.) generating additional heat during operation, thereby improving the thermal environment of the motor controller, helping to extend the life of electronic components, and thus improving the reliability of the system.
[0045] Obviously, the embodiments described above are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of this utility model.
[0046] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.
[0047] The above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.
Claims
1. A motor controller, characterized in that, include: The power device (10) includes a first electrode (11) and a second electrode (12); The capacitor module (20) includes a first conductive structure (21), a second conductive structure (22), and a first insulating structure (23). The first conductive structure (21) is used to be electrically connected to the positive or negative terminal of the power supply. The first insulating structure (23) is disposed between the first conductive structure (21) and the second conductive structure (22). The first electrode (11) is electrically connected to the first conductive structure (21), and the second electrode (12) is electrically connected to the second conductive structure (22).
2. The motor controller according to claim 1, characterized in that, The first conductive structure (21), the first insulating structure (23), and the second conductive structure (22) are stacked in sequence.
3. The motor controller according to claim 2, characterized in that, Projecting along the stacking direction of the first conductive structure (21), the first insulating structure (23), and the second conductive structure (22), the projections of the first conductive structure (21) and the second conductive structure (22) both fall within the projection area of the first insulating structure (23).
4. The motor controller according to any one of claims 1 to 3, characterized in that, The motor controller further includes a second insulation structure (30). There are two power devices (10) and two capacitor modules (20). The two power devices (10) and the two capacitor modules (20) are arranged in a one-to-one correspondence. The two capacitor modules (20) are stacked, and the second conductive structures (22) of the two capacitor modules (20) are arranged adjacent to each other. The second insulation structure (30) is arranged between the two second conductive structures (22).
5. The motor controller according to any one of claims 1 to 3, characterized in that, There are two power devices (10) and two capacitor modules (20). The two power devices (10) share a second electrode (12), and the two capacitor modules (20) share a second conductive structure (22). Along the first direction, the two first insulating structures (23) are arranged opposite to each other on opposite sides of the second conductive structure (22). The two first conductive structures (21) are arranged one-to-one with the two first insulating structures (23). The first conductive structure (21) is located on the side of the corresponding first insulating structure (23) away from the second conductive structure (22).
6. The motor controller according to any one of claims 1 to 3, characterized in that, The motor controller further includes a third conductive structure (40) and a third insulating structure (50). The third conductive structure (40) and the third insulating structure (50) are both disposed on the side of the first conductive structure (21) away from the first insulating structure (23). The third insulating structure (50) is located between the first conductive structure (21) and the third conductive structure (40). One of the first conductive structure (21) and the third conductive structure (40) is connected to the positive terminal of the power supply, and the other of the first conductive structure (21) and the third conductive structure (40) is connected to the negative terminal of the power supply.
7. The motor controller according to claim 6, characterized in that, The first conductive structure (21), the third insulating structure (50), and the third conductive structure (40) are stacked sequentially. Projections are made along the stacking direction of the first conductive structure (21), the third insulating structure (50), and the third conductive structure (40). The projections of the first conductive structure (21) and the third conductive structure (40) both fall within the projection area of the third insulating structure (50).
8. The motor controller according to claim 6, characterized in that, Both the first insulating structure (23) and the third insulating structure (50) are made of insulating materials with a dielectric constant ranging from 5 to 10.
9. The motor controller according to claim 6, characterized in that, The first conductive structure (21), the second conductive structure (22) and the third conductive structure (40) are all made of copper foil or aluminum foil.
10. An electric drive system, characterized in that, include: Electric motor; as well as The motor controller as described in any one of claims 1 to 9.