Low-voltage motor controller of new energy automobile

Abstract

The utility model discloses a low-voltage motor controller of a new energy automobile, and relates to the technical field of automobile parts. Comprising a controller body, and the controller body comprises an aluminum substrate and a first waterproof shell arranged on the top of the aluminum substrate. The same main power board and the same control board can be compatible with two different battery schemes, the difference between the two schemes is that auxiliary source input voltage is different, the auxiliary source input voltage is the same as bus voltage for a vehicle model only equipped with a group of power batteries, the auxiliary source input voltage can be 72V or other input voltage at the moment, and the auxiliary source input voltage and the bus voltage are different. For a vehicle type provided with a storage battery and a power battery at the same time, the input voltage of the auxiliary source is 12V or 24V, and at the moment, only the driving plate needs to be replaced to meet the requirement. According to the design, the material cost is effectively reduced, switching between the waterproof grade IP65 and the waterproof grade IP67 is achieved by replacing the input waterproof shell I and the waterproof shell II, the mold opening cost of structural parts is reduced, and the use requirements of users are met.

Description

Technical Field

[0001] This utility model relates to the field of automotive parts technology, specifically a low-voltage motor controller for new energy vehicles. Background Technology

[0002] With the advancement of new energy in engineering vehicles, low-voltage controllers are widely used in various electric engineering vehicles, such as electric forklifts, tractors, aerial work platforms, warehouse vehicles, sightseeing vehicles, sanitation vehicles, and patrol vehicles. These vehicles may be powered by only one set of power batteries, or equipped with both storage batteries and power batteries.

[0003] The design of the controller needs to take into account the specific needs of different vehicle models, including the configuration of the power battery and the waterproof rating requirements. Due to the variety of vehicle models, the controller needs to be designed into different models to adapt to different situations, which increases the complexity of the design and the cost of mold making. This makes it impossible to simply be compatible with multiple vehicle models, causing serious problems for the manufacturing industry. Summary of the Invention

[0004] To achieve the above objectives, the present invention provides the following technical solution: a low-voltage motor controller for new energy vehicles, comprising a controller body, the controller body comprising an aluminum substrate and a waterproof housing disposed on the top of the aluminum substrate, wherein a main power board, a drive board and a control board are sequentially disposed on the top of the aluminum substrate and located inside the waterproof housing;

[0005] The driver board integrates a driver circuit, an auxiliary power circuit, and several bus capacitors.

[0006] The control board integrates a low-voltage power supply circuit, a microcontroller circuit, a communication circuit, and a voltage and current signal acquisition circuit. The bottom of the drive board is provided with an input copper busbar that extends through to the top of the waterproof housing and a three-phase output aluminum column.

[0007] As a preferred technical solution of this utility model, the drive board is provided with mounting holes for the input copper busbar and the three-phase output aluminum column to pass through.

[0008] As a preferred embodiment of this utility model, the number of input copper busbars is not less than two, and the number of three-phase output aluminum columns is not less than three.

[0009] As a preferred embodiment of this utility model, one end of the control board is provided with a bus port, and the end of the bus port away from the control board extends through to one side of the waterproof housing.

[0010] As a preferred embodiment of this utility model, studs are provided at the four corners of the top of the main power board, and screws are threaded through the four corners of the drive board and screwed into the studs to achieve the connection between the main power board and the drive board.

[0011] As a preferred embodiment of this utility model, the control board is provided with at least one fixing bolt, and the control board is locked inside the waterproof outer shell by the fixing bolt.

[0012] As a preferred technical solution of this utility model, the main power board is a single-sided double-layer aluminum-based PCB, and the bottom of the main power board is coated with a layer of thermal paste and the main power board is bonded to the aluminum substrate through the thermal paste.

[0013] As a preferred embodiment of this utility model, the top and sides of the waterproof outer shell are provided with several heat dissipation grooves, and a sealing ring is also provided between the waterproof outer shell and the aluminum substrate.

[0014] As a preferred technical solution of this utility model, the four corners of the waterproof outer shell are provided with clearance notches for avoiding screws.

[0015] As a preferred technical solution of this utility model, the top of the waterproof housing is provided with a wiring mark on one side of the input copper busbar and the three-phase output aluminum column, and a vent valve is provided on one side of the waterproof housing.

[0016] Compared with the prior art, this utility model provides a low-voltage motor controller for new energy vehicles, which has the following advantages:

[0017] This low-voltage motor controller for new energy vehicles allows the same main power board and control board to be compatible with two different battery solutions. The difference between these two solutions lies in the auxiliary power input voltage. For models equipped with only one power battery, the auxiliary power input voltage is the same as the bus voltage. In this case, the auxiliary power input voltage can be 72V or other input voltages. For models equipped with both a storage battery and a power battery, the auxiliary power input voltage is 12V or 24V. In this case, only the drive board needs to be replaced to meet the requirements. This design effectively reduces material costs and allows switching between IP65 and IP67 waterproof ratings by changing the input waterproof housing one and waterproof housing two, reducing the mold costs of structural components and meeting user needs. Attached Figure Description

[0018] One or more embodiments are illustrated by way of example with reference to the accompanying drawings. These illustrations and drawings do not constitute a limitation on the embodiments. Elements having the same reference numerals in the drawings are shown as similar elements. The drawings are not to be scaled. And wherein:

[0019] Figure 1 This is a schematic diagram of the structure of a low-voltage motor controller for new energy vehicles proposed in this utility model;

[0020] Figure 2This is a schematic diagram of the aluminum substrate structure of a low-voltage motor controller for new energy vehicles proposed in this utility model.

[0021] Figure 3 This is a schematic diagram of the main power board structure of a low-voltage motor controller for new energy vehicles proposed in this utility model;

[0022] Figure 4 This is a schematic diagram of the drive board structure of a low-voltage motor controller for new energy vehicles proposed in this utility model;

[0023] Figure 5 This is a schematic diagram of the control board structure of a low-voltage motor controller for new energy vehicles proposed in this utility model;

[0024] Figure 6 This utility model provides an electrical schematic diagram of the main power board of a low-voltage motor controller for new energy vehicles.

[0025] Figure 7 This is a schematic diagram of the second embodiment of the low-voltage motor controller for new energy vehicles proposed in this utility model.

[0026] In the diagram: 1. Controller body; 11. Aluminum substrate; 12. Waterproof housing one; 121. Heat dissipation groove; 122. Vent valve; 123. Clearance notch; 124. Wiring markings; 13. Main power board; 131. Stud; 14. Driver board; 141. Input copper busbar; 142. Three-phase output aluminum column; 143. Bus capacitor; 144. Auxiliary power circuit; 145. Drive circuit; 146. Mounting hole; 15. Control board; 151. Bus port; 152. Microcontroller circuit; 153. Communication circuit; 154. Low-voltage power supply circuit; 155. Voltage and current signal acquisition circuit; 156. Fixing bolt; 16. Waterproof housing two; 161. Waterproof cover plate; 162. Connector; 163. Waterproof connector. Detailed Implementation

[0027] To provide a more detailed understanding of the features and technical content of the embodiments of this disclosure, the implementation of the embodiments of this disclosure will be described in detail below with reference to the accompanying drawings. The accompanying drawings are for illustrative purposes only and are not intended to limit the embodiments of this disclosure. In the following technical description, for ease of explanation, several details are used to provide a full understanding of the disclosed embodiments. However, one or more embodiments may still be implemented without these details. In other cases, well-known structures and devices may be simplified in their depiction to simplify the drawings.

[0028] The terms "first," "second," etc., used in the specification, claims, and accompanying drawings of this disclosure are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate for the embodiments of this disclosure described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion.

[0029] In this disclosure, the terms "upper," "lower," "inner," "middle," "outer," "front," and "rear," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for better description of the embodiments of this disclosure and their implementations, and are not intended to limit the indicated devices, elements, or components to having a specific orientation, or to require them to be constructed and operated in a specific orientation. Furthermore, some of the aforementioned terms may be used to indicate other meanings besides orientation or positional relationship; for example, the term "upper" may in some cases indicate a dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in the embodiments of this disclosure according to the specific circumstances.

[0030] Furthermore, the terms "set up," "connect," and "fix" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral structure; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, or it can be an internal connection between two devices, components, or parts. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this disclosure according to the specific circumstances.

[0031] Unless otherwise stated, the term "multiple" means two or more.

[0032] It should be noted that, unless otherwise specified, the embodiments and features described in the present disclosure can be combined with each other.

[0033] Please see Figure 1-6A low-voltage motor controller for new energy vehicles includes a controller body 1. The controller body 1 includes an aluminum substrate 11 and a waterproof housing 12 disposed on top of the aluminum substrate 11. A main power board 13, a drive board 14, and a control board 15 are sequentially disposed on the top of the aluminum substrate 11 inside the waterproof housing 12. The drive board 14 integrates a drive circuit 145, an auxiliary power circuit 144, and several bus capacitors 143. The control board 15 integrates a low-voltage power supply circuit 154, a microcontroller circuit 152, a communication circuit 153, and a voltage and current signal acquisition circuit 155. The drive board 14... The bottom of the device features an input copper busbar 141 extending to the top of the waterproof housing 12, and a three-phase output aluminum column 142. This low-voltage motor controller for new energy vehicles allows the same main power board 13 and control board 15 to be compatible with two different battery solutions. The difference between these two solutions lies in the auxiliary power input voltage. For models equipped with only one power battery, the auxiliary power input voltage is the same as the bus voltage, and can be 72V or other input voltages. For models equipped with both storage batteries and power batteries, the auxiliary power input voltage is 12V or 24V, requiring only the drive board 14 to be replaced to meet the requirements. This design effectively reduces material costs and allows switching between IP65 and IP67 waterproof ratings by replacing the input waterproof housing 12 and the waterproof housing 16, reducing the mold costs of structural components and meeting user needs.

[0034] As a specific technical solution in this embodiment, the drive board 14 is provided with mounting holes 146 for the input copper busbar 141 and the three-phase output aluminum column 142 to pass through.

[0035] In this implementation scheme, the main function of bus capacitor 143 is to smooth the bus voltage, ensuring that the bus voltage of the motor controller remains relatively smooth during MOS switching, reducing the inductance parameter of the line from the MOS terminal of the motor controller to the power battery terminal, weakening the peak voltage of the bus, absorbing the high pulse current at the bus terminal of the motor controller, and preventing the overcharging and transient voltage at the bus terminal from affecting the motor controller. The main function of drive circuit 145 is to provide sufficient drive capability. Since the drive signal is often provided by the microcontroller of the controller, the drive voltage and current are often insufficient to turn on the switching transistor, thus requiring a drive circuit. 145 performs drive capability matching to ensure good switching state of the switching transistor, guarantee device reliability, and avoid overvoltage and overcurrent. The main function of the auxiliary power circuit 144 is to convert the auxiliary power input voltage into multiple voltages for use by the control board 15 and the drive circuit 145 respectively. The innovation of this patented solution is that the low-voltage 12V and high-voltage 72V auxiliary power input can be compatible by replacing the auxiliary power transformer on the same board, so as to adapt to different external auxiliary power input conditions and adapt to different battery configuration schemes of vehicle models. The mounting hole 146 is used to install the input copper busbar 141 and the three-phase output aluminum column 142.

[0036] As a specific technical solution of this embodiment, the number of input copper busbars 141 is not less than two, the number of three-phase output aluminum pillars 142 is not less than three, one end of the control board 15 is provided with a bus port 151, the end of the bus port 151 away from the control board 15 extends to one side of the waterproof housing 12, studs 131 are provided at the four corners of the top of the main power board 13, and screws are passed through the four corners of the drive board 14 and screwed into the studs 131 to realize the connection between the main power board 13 and the drive board 14. The control board 15 is provided with not less than one fixing bolt 156, and the control board 15 is locked inside the waterproof housing 12 by the fixing bolt 156.

[0037] In this implementation scheme, the main power board 13 realizes the conversion function of high voltage and high current signal, while the control board 15 plays the role of low voltage and small signal conversion. To realize the function of the main power circuit, the power supply of low voltage power supply and the sampling feedback results of key voltage and current signals are indispensable.

[0038] The control board 15 is the core of the entire solution. The low-voltage power supply circuit 154 on the control board 15 converts the low-voltage power generated by the driver board 14 into multiple voltages of different amplitudes to supply the circuits and chips on the control board 15. The microcontroller on the control board 15 monitors the key signals of the main power board 13 through the signal transmission of the external auxiliary circuit, the sampling function of the voltage and current sampling circuit and other signal sampling circuits, and makes corresponding control methods to ensure that the main power conversion can be carried out stably. The communication circuit 153 on the control board 15 is used to receive and transmit the interactive information between the external device and the microcontroller, receive the control commands of the external device to the low-voltage controller, and upload the module voltage, current, temperature and other information collected by the microcontroller to realize the communication between the module and the external control device.

[0039] As a specific technical solution in this embodiment, the main power board 13 is a single-sided double-layer aluminum-based PCB. The bottom of the main power board 13 is coated with a layer of thermal paste, and the main power board 13 is bonded to the aluminum substrate 11 through the thermal paste.

[0040] In this implementation plan, please refer to Figure 7The main power board 13 receives the DC bus voltage V_BATT+ after filtering by bus capacitors 143C1 and C2 and the ground line CND as input. Through the control of six MOSFETs Q1, Q2, Q3, Q4, Q5, and Q6, the DC power is converted into AC power to supply the three phases of the motor connected to the INV_A, INV_B, and INV_C ports. The PWM signals controlling the MOSFETs are respectively connected to DRV_UH_G, DRV_VH_G, DRV_WH_G, DRV_UL_G, DRV_VL_G, and DRV_WL_G.

[0041] As a specific technical solution of this embodiment, the top and sides of the waterproof outer shell 12 are provided with a plurality of heat dissipation grooves 121, and a sealing ring is also provided between the waterproof outer shell 12 and the aluminum substrate 11.

[0042] In this embodiment, the sealing ring ensures the airtightness between the waterproof outer shell 12 and the aluminum substrate 11. The aluminum substrate 11 has a through hole inside, and a screw is inserted into the interior of the waterproof outer shell 12 from the bottom of the aluminum substrate 11 to fix the waterproof outer shell 12.

[0043] As a specific technical solution in this embodiment, the four corners of the waterproof outer shell 12 are provided with clearance notches 123 for avoiding screws.

[0044] In this embodiment, screws are inserted into all four corners of the aluminum substrate 11, which can be used to fix the aluminum substrate 11 to the vehicle. The clearance notch 123 can avoid the screws used for mounting the aluminum substrate 11. The aluminum substrate 11 can act as a shielding plate to prevent some components in electronic products from being irradiated and interfered with by electromagnetic waves, thus shielding electromagnetic waves and ensuring the performance of electronic circuits. The aluminum substrate 11 has high mechanical strength and toughness, and can withstand a certain amount of external impact. In addition, the aluminum substrate 11 has a fast heat dissipation speed, which can reduce the temperature of electrical products during operation, thereby improving the working efficiency of electrical appliances and extending the life of electrical products.

[0045] As a specific technical solution in this embodiment, a wiring mark 124 is provided on the top of the waterproof housing 12 on one side of the input copper busbar 141 and the three-phase output aluminum column 142, and a vent valve 122 is provided on one side of the waterproof housing 12.

[0046] In this implementation, wiring label 124 facilitates external wiring for users, preventing wiring errors and simplifying the assembly process. The vent valve 122 balances the internal and external air pressure of the controller, preventing deformation or sealing failure of the waterproof housing 12 due to excessive pressure difference. This helps maintain the sealing performance of the waterproof housing 12 and prevents structural damage caused by pressure imbalance. The vent valve 122 prevents water, oil, and other liquids from entering the waterproof housing 12, protecting the equipment from moisture damage. The vent valve 122 typically uses an ePTFE waterproof and breathable membrane, effectively isolating liquids and ensuring normal operation of the equipment in humid environments. The vent valve 122 also blocks dust and other fine particles from entering the waterproof housing 12, preventing dust accumulation that could lead to equipment malfunction or performance degradation. This is crucial for maintaining the cleanliness and long-term stable operation of the equipment. The waterproof housing 12, in conjunction with the aluminum substrate 11, achieves IP65 waterproof rating.

[0047] Example 2, see Figure 1-7 Compared to the above embodiments, this embodiment also includes a second waterproof housing 16, used to replace the first waterproof housing 12 in the above embodiments. The second waterproof housing 16 has at least five waterproof connectors 163 on one side, used for connecting input and output wires respectively. Connecting seats 162 are also provided around the bottom of the second waterproof housing 16, used to screw screws through the bottom of the aluminum substrate 11 into the interior of the connecting seats 162 to fix the second waterproof housing 16. A waterproof cover plate 161 is provided on the top of the second waterproof housing 16. Sealing rings are provided between the waterproof cover plate 161 and the second waterproof housing 16, and between the second waterproof housing 16 and the aluminum substrate 11. The top of the waterproof cover 161 and both sides of the second waterproof housing 16 are provided with heat dissipation grooves 121. The waterproof cover 161 facilitates the inspection and maintenance of the interior of the second waterproof housing 16 without disassembling it. The top of the waterproof cover 161 is also provided with wiring labels 124 corresponding to the waterproof connectors 163. The second waterproof housing 16, in conjunction with the aluminum substrate 11, can achieve IP67 waterproof rating. Only the driver board 14 needs to be replaced. The driver board 14 is connected via the waterproof connectors 163, eliminating the need for the input copper busbar 141 and the three-phase output aluminum pillar 142 wiring method, further improving the overall sealing and waterproof performance.

[0048] In summary, this low-voltage motor controller for new energy vehicles enables the same main power board 13 and control board 15 to be compatible with two different battery solutions. The difference between these two solutions lies in the auxiliary power input voltage. For models equipped with only one power battery, the auxiliary power input voltage is the same as the bus voltage. In this case, the auxiliary power input voltage can be 72V or other input voltages. For models equipped with both storage batteries and power batteries, the auxiliary power input voltage is 12V or 24V. In this case, only the drive board 14 needs to be replaced to meet the requirements. This design effectively reduces material costs and allows switching between IP65 and IP67 waterproof ratings by replacing the input waterproof housing 12 and the waterproof housing 2 16, reducing the mold costs of structural components and meeting user needs.

[0049] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A low-voltage motor controller for new energy vehicles, comprising a controller body (1), characterized in that: The controller body (1) includes an aluminum substrate (11) and a waterproof outer shell (12) disposed on the top of the aluminum substrate (11). The top of the aluminum substrate (11) is sequentially provided with a main power board (13), a drive board (14) and a control board (15) located inside the waterproof outer shell (12). The drive board (14) integrates a drive circuit (145), an auxiliary power circuit (144), and several bus capacitors (143). The control board (15) integrates a low-voltage power supply circuit (154), a microcontroller circuit (152), a communication circuit (153), and a voltage and current signal acquisition circuit (155). The bottom of the drive board (14) is provided with an input copper busbar (141) that extends through to the top of the waterproof outer shell (12) and a three-phase output aluminum column (142).

2. The low-voltage motor controller for new energy vehicles according to claim 1, characterized in that: The drive board (14) has mounting holes (146) inside for the input copper busbar (141) and the three-phase output aluminum column (142) to pass through.

3. A low-voltage motor controller for new energy vehicles according to claim 1, characterized in that: The number of input copper busbars (141) shall not be less than two, and the number of three-phase output aluminum columns (142) shall not be less than three.

4. A low-voltage motor controller for new energy vehicles according to claim 1, characterized in that: One end of the control board (15) is provided with a bus port (151), and the end of the bus port (151) away from the control board (15) extends through to one side of the waterproof housing (12).

5. A low-voltage motor controller for new energy vehicles according to claim 1, characterized in that: The main power board (13) has studs (131) at the top four corners, and the drive board (14) has screws at the four corners that are screwed into the studs (131) to connect the main power board (13) and the drive board (14).

6. A low-voltage motor controller for new energy vehicles according to claim 1, characterized in that: The control board (15) is provided with at least one fixing bolt (156), and the control board (15) is locked inside the waterproof outer shell (12) by the fixing bolt (156).

7. A low-voltage motor controller for new energy vehicles according to claim 1, characterized in that: The main power board (13) is a single-sided double-layer aluminum-based PCB. The bottom of the main power board (13) is coated with a layer of thermal paste and the main power board (13) is bonded to the aluminum substrate (11) through the thermal paste.

8. A low-voltage motor controller for new energy vehicles according to claim 1, characterized in that: The top and sides of the waterproof outer shell (12) are provided with several heat dissipation grooves (121), and a sealing ring is also provided between the waterproof outer shell (12) and the aluminum substrate (11).

9. A low-voltage motor controller for new energy vehicles according to claim 1, characterized in that: The waterproof outer casing (12) has clearance notches (123) at each of its four corners to avoid screws.

10. A low-voltage motor controller for new energy vehicles according to claim 1, characterized in that: Wiring markings (124) are provided on the top of the waterproof housing (12) on one side of the input copper busbar (141) and the three-phase output aluminum column (142), and a vent valve (122) is provided on one side of the waterproof housing (12).

Images