Motor controller structure and vehicle

Abstract

The utility model relates to the field of motor controllers, and discloses a motor controller structure and a vehicle, and the motor controller structure part comprises an upper cover; the shell comprises an enclosure bulkhead, the enclosure bulkhead is fixedly connected with the upper cover, and a mounting cavity is formed between the shell and the upper cover; the circuit module structure comprises a high-voltage module structure and a low-voltage module structure; the low-voltage module support is fixed to the installation cavity, the low-voltage module structure is fixed to the low-voltage module support, the high-voltage module structure is fixed to the installation cavity, and the high-voltage module structure is located below the low-voltage module support. The high-voltage module structure is separated from the low-voltage module structure by the low-voltage module bracket.

Description

Technical Field

[0001] This application relates to the field of motor controller technology, and more particularly to a motor controller structure and a vehicle. Background Technology

[0002] As competition intensifies in the automotive industry, understanding user needs is paramount. While vehicles typically only offer X / Y-axis active control, the motor controller plays a crucial role in fulfilling user demands for vertical (Z-axis) control. The motor controller receives relevant signals from the active suspension control system nodes via the vehicle bus, processes them in real-time through its internal circuit modules, and accurately outputs drive signals to rotate the motor, achieving real-time output of the target torque to the required system.

[0003] The motor controller has many circuit modules, including high-voltage and low-voltage modules. The current approach is to design each circuit module independently and combine them. When the combined system is working, electrical interference can easily occur between the high-voltage and low-voltage modules. Utility Model Content

[0004] This application provides a motor controller structure and vehicle to solve the technical problem that existing motor controller structures are prone to electrical interference between high-voltage and low-voltage modules.

[0005] To address the above problems, this application provides the following solution:

[0006] A motor controller structure includes:

[0007] Top cover;

[0008] A housing, the housing including a surrounding wall, the surrounding wall being fixedly connected to the upper cover, and an installation cavity being formed between the housing and the upper cover;

[0009] The circuit module structure includes a high-voltage module structure and a low-voltage module structure.

[0010] A low-voltage module bracket is fixed to the mounting cavity. The low-voltage module structure is fixed on the low-voltage module bracket. The high-voltage module structure is fixed to the mounting cavity. The high-voltage module structure is located below the low-voltage module bracket. The high-voltage module structure and the low-voltage module structure are separated by the low-voltage module bracket.

[0011] Furthermore, the circuit module structure also includes a conductive connection bus structure, and the high-voltage module structure includes a high-voltage drive module structure and a high-voltage power module structure;

[0012] Both the high-voltage drive module structure and the high-voltage power module structure are fixed in the mounting cavity, and the circuit modules in the high-voltage drive module structure and the high-voltage power module structure are respectively connected to the corresponding conductive connection points of the conductive connection bar structure.

[0013] Furthermore, the motor controller structure also includes a first connecting row fixing bracket and a second connecting row fixing bracket;

[0014] The first connecting bar fixing bracket and the second connecting bar fixing bracket are respectively fixed to the two ends of the mounting cavity in the first direction, and the two ends of the conductive connecting bar structure are respectively fixed to the first connecting bar fixing bracket and the second connecting bar fixing bracket.

[0015] Furthermore, the low-voltage module bracket includes multiple low-voltage module structure mounting points, and the low-voltage module bracket is provided with a bracket reinforcing rib structure.

[0016] Furthermore, the bottom wall of the housing is provided with an EMC module mounting structure, and the circuit module structure also includes an EMC module structure, which is fixed to the EMC module mounting structure.

[0017] Furthermore, the outer wall of the enclosure is provided with a cooling water outlet and a cooling water inlet, and the bottom wall of the shell is provided with a cooling water passage, the outlet of the cooling water passage is connected to the cooling water outlet, and the inlet of the cooling water passage is connected to the cooling water inlet.

[0018] Furthermore, the motor controller structure also includes a cooling water circuit sealing plate. A notch is provided on the outer wall of the bottom wall of the housing. The cooling water circuit is located in the notch, and the cooling water circuit sealing plate is sealed to the notch.

[0019] Furthermore, the outer wall surface of the enclosure is provided with multiple high-voltage plug-in installation structures of different plug-in types.

[0020] Furthermore, the enclosure includes a first side wall, a second side wall, a third side wall, and a fourth side wall, which together form the enclosure. Multiple high-voltage plug-in mounting structures are disposed on the outer wall surface of the same side wall.

[0021] Furthermore, the outer walls of the other side walls in the enclosure that are not equipped with the high-voltage plug-in installation structure are respectively provided with shell external installation structures.

[0022] Furthermore, the high-voltage plug-in mounting structure includes a DC high-voltage plug-in mounting structure, a low-voltage plug-in mounting structure, and one or more motor high-voltage plug-in mounting structures.

[0023] Furthermore, the high-voltage plug-in mounting structure also includes a damping resistor plug-in mounting structure, which is used to install the damping resistor plug-in module.

[0024] Furthermore, one end of the mounting cavity in the second direction is provided with a pre-charge capacitor module mounting structure for mounting the pre-charge capacitor module.

[0025] Furthermore, the upper cover is provided with a cover reinforcement rib structure on the inner wall surface facing the housing.

[0026] A vehicle comprising a motor controller structure as described in any of the preceding claims.

[0027] As can be seen, this application provides a motor controller structure. Through the structural relationship between the low-voltage module bracket and the low-voltage module structure and the high-voltage module structure, the internal structure of the motor controller structure is designed in a layered manner. Since the high-voltage module structure is used to assemble the high-voltage module and the low-voltage module structure is used to assemble the low-voltage module, the low-voltage module and the structure involving the high-voltage module in the motor controller structure can be arranged in layers through the layered design. In this way, when the circuit system of the motor controller structure is working, the electrical interference of the high-voltage module to the low-voltage module can be effectively avoided or reduced. Attached Figure Description

[0028] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the description of the embodiments of this application will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0029] Figure 1 This is a schematic diagram of the overall structure of a motor controller according to one embodiment of this application;

[0030] Figure 2 yes Figure 1 A cross-sectional schematic diagram of positions AA and BB in the middle section;

[0031] Figure 3 This is a top view of the housing structure of a motor controller according to one embodiment of this application;

[0032] Figure 4 This is a schematic diagram of one side view of the housing structure of a motor controller according to an embodiment of this application;

[0033] Figure 5 This is a front and back structural diagram of the upper cover of a motor controller structure according to an embodiment of this application;

[0034] Figure 6 This is a schematic diagram of one side structure of the housing of a motor controller structure according to one embodiment of this application;

[0035] Figure 7 This is a schematic diagram showing an arrangement of external connectors, water outlet, and water inlet of a motor controller structure according to one embodiment of this application;

[0036] Figure 8 This is a schematic diagram of the bottom wall structure of a housing of a motor controller structure according to an embodiment of this application;

[0037] Figure 9 This is a schematic diagram of a cooling water circuit sealing plate structure of a motor controller structure according to one embodiment of this application;

[0038] Figure 10 This is a schematic diagram of the conductive connection bar structure of a motor controller structure according to one embodiment of this application;

[0039] Figure 11 This is a schematic diagram of the structure of a first connecting row fixing bracket and a second connecting row fixing bracket of a motor controller structure according to an embodiment of this application;

[0040] Figure 12 This is a schematic diagram of the first high-voltage power module structure and the second high-voltage power module structure of a motor controller structure according to an embodiment of this application;

[0041] Figure 13 This is a schematic diagram of a high-voltage drive module structure of a motor controller according to one embodiment of this application;

[0042] Figure 14 This is a schematic diagram of a low-voltage module bracket for a motor controller structure according to one embodiment of this application;

[0043] Figure 15 This is a schematic diagram of a low-voltage module structure of a motor controller according to one embodiment of this application;

[0044] Figure 16 This is a schematic diagram of an EMC module structure of a motor controller according to one embodiment of this application;

[0045] Figure 17 This is a schematic diagram of a pre-charge capacitor module structure of a motor controller structure according to one embodiment of this application;

[0046] Figure 18 This is a schematic diagram of a damping resistor module of a motor controller structure according to one embodiment of this application;

[0047] Figures 19-20This is a schematic diagram of an assembly process of a motor controller structure according to an embodiment of this application;

[0048] Figure 21 This is a schematic diagram of the working process of a motor controller structure in normal working mode according to an embodiment of this application;

[0049] Figure 22 This is a schematic diagram of the working process of a motor controller structure in passive damping resistor working mode according to an embodiment of this application;

[0050] Figure label:

[0051] 1. Top cover; 104. Cover body reinforcing rib structure; 105. First positioning mounting hole; 106. Second positioning mounting hole;

[0052] 2. Housing 2, Enclosure 21, Mounting Cavity 22, Pre-charge Capacitor Module Mounting Structure 221, Bottom Wall 23, Recess 231, Cooling Water Channel 24, First Side Wall 211, Second Side Wall 212, Third Side Wall 213 and Fourth Side Wall 214, DC High Voltage Plug-in Mounting Structure 2111, Low Voltage Plug-in Mounting Structure 2112, First Motor High Voltage Plug-in Mounting Structure 2113, Second Motor High Voltage Plug-in Mounting Structure 2114, Damping Resistor Plug-in Mounting Structure 2115, Cooling Water Outlet Mounting Port 2116, Cooling Water Inlet Mounting Port 2117, Top Cover Mounting Point 201, First High Voltage Power Module Structure Mounting Point 202A, EMC Module Structure Mounting Points 1 & 2 Mounting points 203A, 3, 4, and 5 of the EMC module structure; 203B of the second high-voltage power module structure; 202B of the second high-voltage power module structure; 204A of the pre-charge capacitor module structure; 204B of the pre-charge capacitor module structure; 205A of the low-voltage module bracket; 205B of the low-voltage module bracket; 205C of the low-voltage module bracket and 205D of the low-voltage module bracket; 206A of the high-voltage drive module structure; 206B of the high-voltage drive module structure; 207A of the first connecting row fixing bracket; and 207B of the second connecting row fixing bracket.

[0053] 3. Pre-charge capacitor module structure; 31. High voltage + / - connection point of backup power module; 33. Pre-charge capacitor module; 33. Capacitor mounting point;

[0054] Low-voltage module bracket 4, low-voltage module structure mounting point 41, bracket reinforcing rib structure 42, shell mounting point 43;

[0055] Cooling water circuit sealing plate 5;

[0056] The high-voltage drive module structure 6 includes: a three-phase power output connection point 61 for the first motor, a three-phase power output connection point 62 for the second motor, a high-voltage DC+ / DC- connection point 63 for the DC bus, and an internal + / - connection point 64 for the damping resistor module.

[0057] Conductive connection bus structure 7, copper bus mounting point 71, first layer of copper bus 72, second layer of copper bus 73, third layer of copper bus 74, C / E pin of power device of high voltage power module 721, three-phase current output pin inside motor controller 722, DC- pin connected to pre-charge capacitor module 731, DC- pin of EMC module 732, DC+ pin connected to pre-charge capacitor module 741, DC+ pin of EMC module 742;

[0058] EMC module structure 8, housing mounting point 81, Y capacitor 82, welding via 83;

[0059] The low-voltage module structure 9 includes a main board 91, a + / - connection point 911 for the backup power module, a bracket mounting point 912, an internal plug-in for low-voltage control signals 913, an internal plug-in for low-voltage information output 914, and an internal plug-in for high-voltage interlock module output 915.

[0060] First connecting row fixing bracket 10, first bracket mounting hole 101;

[0061] The first high-voltage power module structure 11 includes a first substrate 111, mounting holes 1111, a power device 1112 corresponding to the V-phase circuit of the first motor, a power device 1113 corresponding to the V-phase circuit of the second motor, a power device 1114 corresponding to the U-phase circuit of the second motor, a power device 1115 corresponding to the W-phase circuit of the second motor, and a temperature signal plug-in 1116 for the first high-voltage power module.

[0062] The second high-voltage power module structure 12 includes a second substrate 121, mounting holes 1211, a power device 1212 corresponding to the DC bus control switch, a power device 1213 corresponding to the U-phase circuit of the first motor, a power device 1214 corresponding to the W-phase circuit of the first motor, a power device 1215 corresponding to the damping resistor module switch, and a second high-voltage power module temperature signal plug-in 1216.

[0063] Second connecting row fixing bracket 13, second bracket mounting hole 131;

[0064] Cooling water outlet nozzle 14;

[0065] DC high voltage plug-in module 15;

[0066] First motor high voltage plug-in module 16;

[0067] Second motor high voltage plug-in module 17;

[0068] Damping resistor plug-in module 18;

[0069] Low-voltage plug-in module 19;

[0070] Cooling water inlet nozzle 20. Detailed Implementation

[0071] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0072] This application provides a motor controller structure, including various circuit module structures and corresponding circuit modules of the motor controller, assembled to form the motor controller structure of this application embodiment. The motor controller implemented based on the motor controller structure provided in this application embodiment can be applied to various motor systems, including but not limited to the motor control of active suspension control systems, servo systems, and main drive systems. The active suspension control system may include an electromagnetic active suspension control system, and is not specifically limited thereto. For example, taking an active suspension control system as an example, the motor controller implemented using the motor controller structure provided in this application embodiment can receive real-time target torque requests, operating mode requests, physical angle requests, and other related signals issued by the active suspension control system nodes through the vehicle bus. After real-time control processing by the internal circuit modules of the motor controller structure in this application embodiment, it accurately issues drive signals to drive the suspension motor to work, thereby achieving real-time output of the target torque to the required active suspension control system.

[0073] It should be emphasized that the motor controller structure provided in this application mainly describes its structural design. Based on this motor controller structure, the connection relationship of its internal circuit modules is not limited in this application. The electrical connection relationship between circuit modules is only illustrative in the following explanation of the embodiments and does not constitute a specific limitation.

[0074] Please refer to the following: Figures 1-19 As shown in the embodiments of this application, a motor controller structure is provided. This motor controller structure is used for assembling various circuit module structures. The circuit module structure is equipped with circuit modules, and the circuit modules in the motor controller structure are interconnected to form the final motor controller physical structure. The motor controller structure includes:

[0075] Top cover 1;

[0076] The housing 2 includes a surrounding wall 21, which is fixedly connected to the upper cover 1, and an installation cavity 22 is formed between the housing 2 and the upper cover 1;

[0077] The circuit module structure includes a high-voltage module structure and a low-voltage module structure 9;

[0078] A low-voltage module bracket 4 is fixed to the mounting cavity 22. The low-voltage module structure 9 is fixed to the low-voltage module bracket 4. The high-voltage module structure is fixed to the mounting cavity 22. The high-voltage module structure is located below the low-voltage module bracket 4. The high-voltage module structure and the low-voltage module structure 9 are separated by the low-voltage module bracket 4.

[0079] It should be understood that the motor controller structure includes various circuit modules required for operation, including high-voltage modules and low-voltage modules, referred to as high-voltage modules and low-voltage modules respectively in this embodiment. The specific high-voltage and low-voltage modules included depend on the circuit design of the motor controller and are not limited thereto. Examples will be provided in the following sections to illustrate these points, and will not be elaborated upon here. In this embodiment, the high-voltage module structure 9 is used to assemble the high-voltage module, and the low-voltage module structure 9 is used to assemble the low-voltage module.

[0080] As can be seen, this application embodiment provides a motor controller structure. Through the structural relationship between the low-voltage module bracket 4, the low-voltage module structure 9, and the high-voltage module structure, the internal structure of the motor controller structure is designed in a layered manner. Since the high-voltage module structure is used to assemble the high-voltage module, and the low-voltage module structure 9 is used to assemble the low-voltage module, the low-voltage module and the structure involving the high-voltage module in the motor controller structure can be arranged in layers through the layered design. In this way, when the circuit system of the motor controller structure is working, the electrical interference of the high-voltage module to the low-voltage module can be effectively avoided or reduced.

[0081] In one embodiment, the circuit module structure further includes a conductive connection bar structure 7. The high-voltage module structure includes a high-voltage drive module structure 6 and a high-voltage power module structure. Both the high-voltage drive module structure 6 and the high-voltage power module structure are fixed in the mounting cavity 22. The circuit modules in the high-voltage drive module structure 6 and the high-voltage power module structure are connected to the corresponding conductive connection points of the conductive connection bar structure 7. The circuits in the conductive connection bar structure are used for other electrical connection points to interact with each other, thereby realizing the corresponding circuit functions of the high-voltage drive module in the high-voltage drive module structure 6 and the corresponding circuit functions of the high-voltage power module structure in the high-voltage power module structure.

[0082] In this embodiment, in order to realize the centralized layout of each circuit module in the motor controller structure, this embodiment also includes a conductive connection bar structure 7. The conductive connection bar structure is used to realize the interconnection relationship of each circuit module in the motor controller, thereby realizing the circuit module function of the motor controller structure.

[0083] As an example, such as Figure 7 As shown, the conductive connection bus structure 7 can be a three-layer stacked copper bus structure. The stacked copper bus structure includes copper bus mounting points 71 (e.g., 4) and three layers of copper bus. The first layer 72 of the copper bus can include a high-voltage DC to AC output layer, a DC+ input layer of the DC bus, and a damping resistor switch connection layer. For example, the first layer 72 of the copper bus can include the C / E pins 721 of the power devices of the high-voltage power module (e.g., two for each power device, distributed around the perimeter) and the three-phase current output pins 722 inside the motor controller (e.g., three three-phase current output pins of the first motor and three three-phase current output pins of the second motor, distributed around the perimeter). The second layer 73 of the copper bus can include the vehicle DC- layer (e.g., DC- pin 731 connected to the pre-charge capacitor module and DC- pin 732 of the EMC module) and the E- terminal of the switching unit controlling the motor. The third layer 74 of the copper bus can include the vehicle DC+ layer (e.g., DC+ pin 741 connected to the pre-charge capacitor module and DC+ pin 742 of the EMC module), etc.

[0084] It should be understood that, based on Figure 7 The conductive busbar structure 7 allows the relevant circuit modules in the motor controller to achieve the required connections. For example, the DC- and DC+ terminals of the pre-charge capacitor module can be connected to the corresponding DC- and DC+ pins of the stacked copper busbar structure, respectively. Additionally, this... Figure 7 This is for illustrative purposes only. Depending on the circuit design of the motor controller, there may be other conductive busbar structures, and no specific limitation is made.

[0085] As an example, consider a motor controller that includes a first motor and a second motor, such as... Figure 12The high-voltage power module structure may include a first high-voltage power module structure 11 (which can be understood as the left-side high-voltage power module) and a second high-voltage power module structure 12 (which can be understood as the right-side high-voltage power module structure). The first high-voltage power module structure 11 includes a first substrate 111 and four mounting holes 1111 disposed on the first substrate 111, as well as power devices mounted on the first substrate 111. The power devices mounted on the first substrate 111 may include a power device 1112 corresponding to the V-phase circuit of the first motor, a power device 1113 corresponding to the V-phase circuit of the second motor, a power device 1114 corresponding to the U-phase circuit of the second motor, and a power device 1115 corresponding to the W-phase circuit of the second motor. 115, a total of 8 power devices; similarly, the second high-voltage power module structure 12 includes a second substrate 121 and four mounting holes 1211 disposed on the second substrate 121, as well as power devices mounted on the second substrate 121. The power devices mounted on the second substrate 121 may include power device 1212 corresponding to the DC bus control switch, power device 1213 corresponding to the U-phase circuit of the first motor, power device 1214 corresponding to the W-phase circuit of the first motor, and power device 1215 corresponding to the damping resistor module switch, for a total of 7 power devices. The above power devices can be IGBT transistors, etc. The first substrate 111 and the second substrate 121 can be welded aluminum substrates, etc., and are not specifically limited. It should be understood that the V-phase circuit, U-phase circuit, and W-phase circuit of the first motor refer to the drive circuits where the three-phase drive current of the first motor is located, and each drive circuit has a corresponding power device. The driving of the second motor and the circuit involved in the driving process of the second motor will not be described in detail here.

[0086] Furthermore, as an example, a first high-voltage power module temperature signal plug-in 1116 may be provided at one end of the first substrate 111. The first high-voltage power module temperature signal plug-in 1116 can be used to detect the temperature of the first substrate 111. A second high-voltage power module temperature signal plug-in 1216 may be provided at both ends of the second substrate 121. The second high-voltage power module temperature signal plug-in 1216 can be used to detect the temperature of the second substrate 121. Therefore, the temperature detection module connected to the above-mentioned signal plug-in can collect a temperature signal characterizing the substrate temperature.

[0087] It should be noted that, based on Figure 12 The high-voltage power module structure allows for the necessary assembly relationships between the relevant high-voltage power modules within the motor controller. Figure 12 The high-voltage power module structure, including the mounting hole design of the high-voltage power module structure, is only an example for illustration. Other conductive connection bus structures are also possible, and no specific limitation is made.

[0088] In one embodiment, such as Figure 13As shown, taking a motor controller including a first motor and a second motor as an example, the high-voltage drive module structure 6 includes a three-phase power output connection point 61 for the first motor, a three-phase power output connection point 62 for the second motor, a DC bus high-voltage DC+ / DC- connection point 63, an internal + / - connection point 64 for the damping resistor module, an internal plug-in 65 for the low-voltage control signal, and a mounting point 66 for matching and installing with the housing. For example, the mounting point 65 may include four points, located around the perimeter, but the specific location is not limited.

[0089] Specifically, the first motor three-phase output connection point 61 is used for the three-phase power connection of the first motor; the second motor three-phase output connection point 62 is used for the three-phase power connection of the second motor; the DC bus high-voltage DC+ / DC- connection point 63 is used for connection to the DC bus high-voltage DC+ / DC- terminal; the damping resistor module internal + / - connection point 64 is used for connection to the damping resistor module's + / - point; and the low-voltage control signal internal plug-in 65 is used for connection to the low-voltage control signal circuit module in the motor controller related to the high-voltage drive module structure. It should be understood that the high-voltage drive module structure 6 can realize the driving function of the rolling mill drive module, thereby completing the driving of the high-voltage power module, enabling the high-voltage power module to output drive signals to the first motor or the second motor, thus achieving motor control.

[0090] It should be noted that, based on Figure 13 The high-voltage drive module structure shown can be assembled with the relevant high-voltage drive module in the motor controller, and thus assembled into the housing 2. Figure 13 The high-voltage drive module structure, including the design of the mounting holes and the location of the wiring points, is only an example in this application embodiment. Other high-voltage drive module structures are also possible, and no specific limitation is made.

[0091] In one embodiment, such as Figure 11 As shown, the motor controller structure also includes a first connecting row fixing bracket 10 and a second connecting row fixing bracket 13;

[0092] The first connecting busbar fixing bracket 10 and the second connecting busbar fixing bracket 13 are respectively fixed to the two ends of the mounting cavity in a first direction. For example, taking the figure in the embodiment of this application as an example, the first direction is the length direction of the motor controller structure, and the two ends of the conductive connecting busbar structure 7 are respectively fixed to the first connecting busbar fixing bracket 10 and the second connecting busbar fixing bracket 13. Specifically, for example, the first connecting busbar fixing bracket 10 includes two first bracket mounting holes 101, and the second connecting busbar fixing bracket 13 includes two second bracket mounting holes 131. The conductive connecting busbar structure 7 is assembled and fixed with the corresponding bracket mounting holes of the first connecting busbar fixing bracket 10 and the second connecting busbar fixing bracket 13 through its four copper busbar mounting points 71, thereby realizing the separate connection of the conductive connecting busbar structure 7 with the first connecting busbar fixing bracket 10 and the second connecting busbar fixing bracket 13.

[0093] In this embodiment, in order to facilitate integration and simplify the structural design of the motor controller, an integrated design is adopted. The circuit modules are integrated into the same motor controller and structure with the conductive connection bar structure 7 through a reasonable structural layout. This reduces the number of parts and weight. At the same time, for easy installation, a first connection bar fixing bracket 10 and a second connection bar fixing bracket 13 are also provided to facilitate the assembly of the conductive connection bar structure 7.

[0094] In one embodiment, such as Figure 14 As shown, the low-voltage module bracket 4 includes multiple low-voltage module structure mounting points 41, and the low-voltage module bracket is provided with a bracket reinforcing rib structure 42. For example, the low-voltage module mounting points 41 may include, for instance... Figure 14 The nine mounting points shown can be, specifically, mounting holes, of the low-voltage module 41, and are not limited thereto.

[0095] In addition, the low-voltage module bracket 4 also includes a housing mounting point 43. For example, the housing mounting point 43 can be a mounting hole for installation with the housing 2 to fix the low-voltage module bracket 4 on the housing 2.

[0096] In this embodiment, the low-voltage module bracket 4 includes multiple low-voltage module structure mounting points 41, allowing low-voltage module structures 9 to be installed on the low-voltage module bracket 4. This separates the low-voltage modules from the high-voltage modules below the low-voltage module bracket 4, resulting in a more compact and smaller overall structure. Furthermore, the low-voltage module bracket 4 is equipped with a bracket reinforcing rib structure 42, which improves the bracket strength and overall structural strength, accommodating the installation of multiple low-voltage module structures 9.

[0097] For example, such as Figure 15As shown, the low-voltage module structure 9 includes a main body substrate 91, which is provided with a + / - connection point 911 for the backup power module, a bracket mounting point 912 (exemplary, such as 9 points), an internal plug-in 913 for low-voltage control signals, an internal plug-in 914 for low-voltage information output, and an internal plug-in 915 for high-voltage interlock module output. The bracket mounting point 912 is used to fix it to the low-voltage module bracket 4.

[0098] In this embodiment, the low-voltage module structure 9 includes a main board 91. The main board 91 is provided with a + / - connection point 911 for the backup power module, a bracket mounting point 912, an internal plug-in 913 for low-voltage control signals, an internal plug-in 914 for low-voltage information output, and an internal plug-in 915 for high-voltage interlock module output. The + / - connection point 911 facilitates connection between the low-voltage module and the + / - terminals of the backup power module, thereby providing backup power to the low-voltage module. The internal plug-in 913 connects to the low-voltage module to provide low-voltage control signals from the motor controller. The internal plug-in 914 provides low-voltage information, and the internal plug-in 915 enables the high-voltage interlock module to output signals. It can be seen that the low-voltage module structure 9 integrates various connection points / plug-ins related to low-voltage control, facilitating the implementation of the required low-voltage control functions.

[0099] In one embodiment, the bottom wall 23 of the housing 2 is further provided with an EMC module mounting structure, and the circuit module structure further includes an EMC module structure 8, which is fixed to the EMC module mounting structure and is used to assemble the EMC module.

[0100] As an example, such as Figure 16 As shown, the EMC module structure 8 includes multiple housing mounting points 81 (exemplary, such as 5) for assembling the housing 2. The housing mounting points 81 can be mounting holes. The two ends of the EMC module structure 8 also include Y capacitors 82 for connecting to the DC bus high voltage DC+ and DC bus high voltage DC-, and also include welding vias 83 (exemplary, such as 2). The welding vias 83 can be used for the vias of the copper bus pins of the DC bus high voltage DC+ and DC bus high voltage DC-, and are not specifically limited.

[0101] In this embodiment, the bottom wall 23 of the housing 2 is also provided with an EMC module mounting structure to facilitate the installation of the EMC module structure. The EMC module structure 8 includes multiple housing mounting points 81 for assembling the housing 2, which facilitates installation onto the housing. The two ends of the EMC module structure 8 also include Y capacitors 82 for connecting to the DC bus high voltage DC+ and DC bus high voltage DC-, thereby realizing the EMC function.

[0102] As can be seen, this embodiment greatly simplifies the structural design of the motor controller. It adopts an integrated design, which integrates the low-voltage module, high-voltage drive module, high-voltage power module and EMC module into the same cavity through a reasonable structural design layout, which can reduce the number of parts and weight.

[0103] In one embodiment, such as Figure 1 , 4 As shown in Figure 6, the outer wall surface of the enclosure 21 of the housing 2 is provided with multiple high-voltage plug-in mounting structures of different plug-in types. In this embodiment, the outer wall surface of the enclosure 21 is provided with multiple high-voltage plug-in mounting structures of different plug-in types, which facilitates the insertion of different high-voltage plug-in modules through the corresponding high-voltage plug-in mounting structures.

[0104] In one embodiment, such as Figure 4 As shown, the enclosure 21 includes a first side wall 211, a second side wall 212, a third side wall 213, and a fourth side wall 214. The first side wall 211, the second side wall 212, the third side wall 213, and the fourth side wall 214 enclose the enclosure 21. Multiple high-voltage plug-in mounting structures are disposed on the outer wall surface of the same side wall. For example, all of the multiple high-voltage plug-in mounting structures may be disposed on the outer wall surface of the first side wall 211; the specific arrangement is not limited.

[0105] For example, such as Figure 4 As shown, the outer wall surface of the first side wall 211 of the enclosure 21 is provided with multiple high-voltage plug-in installation structures of different plug-in types. The high-voltage plug-in installation structures include a DC high-voltage plug-in installation structure 2111, a low-voltage plug-in installation structure 2112, and one or more motor high-voltage plug-in installation structures. For example, multiple motor high-voltage plug-in installation structures may refer to a first motor high-voltage plug-in installation structure 2113 and a second motor high-voltage plug-in installation structure 2114.

[0106] In one embodiment, the high-voltage plug-in mounting structure further includes a damping resistor plug-in mounting structure 2115, which is used to mount the damping resistor plug-in module 18. For example, as Figure 4 As shown, the outer wall surface of the first side wall 211 of the enclosure 21 is also provided with the damping resistor plug-in mounting structure 2115. The DC high voltage plug-in mounting structure 2111, the low voltage plug-in mounting structure 2112, the first motor high voltage plug-in mounting structure 2113, the second motor high voltage plug-in mounting structure 2114, the damping resistor plug-in mounting structure 2115, and the low voltage plug-in mounting structure 2112 are arranged in this manner and are respectively on the outer wall surface of the first side wall 211.

[0107] As can be seen, in this embodiment, by designing the damping resistor plug-in mounting structure 2115 as an external structure, the limitations of the overall motor controller structure layout can be reduced, and the passive damping module is released in the passive damping working mode.

[0108] like Figure 6 As shown in Figure 7, the DC high-voltage plug-in mounting structure 2111 is used to plug in the DC high-voltage plug-in module 15, the first motor high-voltage plug-in mounting structure 2113 is used to plug in the first motor high-voltage plug-in module 16, the second motor high-voltage plug-in mounting structure 2114 is used to plug in the second motor high-voltage plug-in module 17, the damping resistor plug-in mounting structure 2115 is used to plug in the damping resistor plug-in module 18, and the low-voltage plug-in mounting structure 2112 is used to plug in the low-voltage plug-in module 19. It should be noted that the above plug-in modules are used to electrically connect with the relevant internal circuit modules of the motor controller, thereby realizing the corresponding circuit functions. For example, the first motor high-voltage plug-in module 16 is a connector related to the high-voltage control of the motor controller and the first motor, mainly used to connect the first motor and the motor controller; the second motor high-voltage plug-in module 17 is a connector related to the high-voltage control of the motor controller and the second motor, mainly used to connect the second motor and the motor controller. The low-voltage plug-in module 19 is typically used to connect low-power devices such as sensors, switches, buttons, and indicator lights on the vehicle to monitor and control the motor's operating status and performance.

[0109] In one embodiment, the enclosure 21 is provided with a cooling water outlet and a cooling water inlet, which are used to connect to a cooling water system, such as a vehicle's cooling water treatment system. A cooling water passage 24 is provided inside the bottom wall of the housing, with its outlet connected to the cooling water outlet and its inlet connected to the cooling water inlet. In this way, the cooling water treatment system can cool the housing through the cooling water passage 24. In particular, in this embodiment, the high-voltage module is located at the bottom of the housing 2, allowing for efficient cooling of the high-voltage module. By designing the cooling water passage 24 inside the motor controller structure to remove the heat generated by the high-power module during operation, overheating is prevented from causing performance degradation or functional failure. Furthermore, the cooling water passage 24 allows for external assembly via the cooling water outlet and inlet, employing a quick-connect structure to improve installation efficiency.

[0110] For example, such as Figure 4 As shown in Figure 6, the first side wall 211 of the enclosure 21 is provided with a cooling water outlet 2116 and a cooling water inlet 2117. The cooling water outlet 2116 is connected to the cooling water system via a cooling water outlet nozzle 14, and the cooling water inlet 2117 is connected to the cooling water system via a cooling water inlet nozzle 20.

[0111] In one embodiment, such as Figure 8 and Figure 9 As shown, the motor controller structure also includes a cooling water circuit sealing plate 5. A notch 231 is provided on the outer wall of the bottom wall 23 of the housing. The cooling water circuit 24 is located in the notch 231. The cooling water circuit sealing plate 5 is sealed to the edge of the notch 231.

[0112] In this embodiment, by providing a notch 231 on the outer wall surface of the bottom wall 23 of the housing and achieving a sealed connection with the cooling water passage sealing plate 5, it is convenient to assemble and maintain the cooling water passage 24.

[0113] In one embodiment, the outer walls of the other side walls of the enclosure 21 that are not equipped with the high-voltage plug-in mounting structure are respectively provided with shell external mounting structures. For example, such as Figure 8 As shown, the outer walls of the second side wall 212, the third side wall 213, and the fourth side wall 214 of the enclosure 21 are each provided with a shell external mounting structure. The outer wall of the second side wall 212 is provided with a shell external mounting structure 2121, the outer wall of the third side wall 213 is provided with a shell external mounting structure 2131, and the outer wall of the fourth side wall 214 is provided with a shell external mounting structure 2141. All three shell external mounting structures are arranged close to the bottom of the shell. The specific form of the shell external mounting structure is not limited and can be in the form of a mounting hole.

[0114] In one embodiment, such as Figure 3 As shown, the mounting cavity 22 is provided with a pre-charged capacitor module mounting structure 221 for mounting the pre-charged capacitor module structure 3 at one end in the second direction (such as the width direction of the mounting cavity 22).

[0115] For example, such as Figure 17 As shown, the pre-charged capacitor module structure 3 includes a high-voltage + / - connection point 31 of the backup power module, a pre-charged capacitor module 33 (e.g., 4 modules), and capacitor mounting points 33 (e.g., 4 points). The mounting points 33 can be in the form of mounting holes, and there is no specific limitation.

[0116] In this embodiment, a pre-charged capacitor module mounting structure 221 is provided at one end of the mounting cavity 22 in the second direction (such as the width direction of the mounting cavity 22), specifically located at the side end of the mounting cavity 22 in the second direction.

[0117] In one embodiment, such as Figure 5As shown, the upper cover 1 has a cover reinforcing rib structure 104 on its inner wall surface facing the housing. As an example, the upper cover 1 also has a first positioning mounting hole 105 and a second positioning mounting hole 106 at both ends for fixed connection with the housing 2. The upper cover 1 is fixedly connected to the corresponding mounting points of the housing 2 through the positioning mounting holes.

[0118] As an example, such as Figure 3 As shown, the housing 2 also includes: a top cover mounting point 201, a first high-voltage power module structure mounting point 202A, EMC module structure mounting points 1 & 2 (203A), EMC module structure mounting points 3 & 4 & 5 (203B), a second high-voltage power module structure mounting point 202B, pre-charge capacitor module structure mounting points 1 & 2 (204A), pre-charge capacitor module structure mounting points 3 & 4 (204B), a low-voltage module bracket mounting point 1 (205A), a low-voltage module bracket mounting point 2 (205B), a low-voltage module bracket mounting point 3 (205C) and a low-voltage module bracket mounting point 4 (205D), a high-voltage drive module mounting point 1 & 2 (206A), a high-voltage drive module mounting point 3 & 4 (206B), a first connecting bar fixing bracket mounting point 207A, and a second connecting bar fixing bracket mounting point 207B. This housing 2. The housing is fixedly connected to the various circuit module structures mentioned in the embodiments of this application through the various mounting points described above, as detailed in the corresponding descriptions above.

[0119] It should be noted that the above-described arrangement and form of the mounting points of the housing 2 involved in the embodiments of this application are merely illustrative examples and do not limit the embodiments of this application.

[0120] The above describes the structure of the motor controller involved in the embodiments of this application. The following is a description in conjunction with... Figures 19-20 The assembly process of the motor controller structure is described, including:

[0121] In this embodiment, during assembly, the cooling water circuit sealing plate 5 is first friction-welded to the bottom back of the housing 2. The second step involves sequentially fixing the first connecting bar fixing bracket 10, the second connecting bar fixing bracket 13, the EMC module structure 8, the first high-voltage power module structure 11, and the second high-voltage power module structure 12 to the corresponding mounting holes on the bottom of the housing 2 using bolts. The third step involves fixing the conductive connecting bar structure 7 to the corresponding mounting holes on the connecting bar fixing bracket using bolts. The fourth step involves fixing the pre-charge capacitor module structure 3 to the corresponding mounting holes on the housing 2. The fifth step involves attaching the high-voltage drive module structure... After fixing the structure 6 to the corresponding mounting holes on the housing 2, solder the relevant pins of the conductive connector structure 7 to the corresponding circuit module connection points. The sixth step involves fixing each high-voltage plug-in module sequentially to the high-voltage plug-in mounting structure on the housing 2 and connecting the internal high-voltage wiring points. The seventh step involves fixing the low-voltage module bracket 4 to the corresponding mounting holes on the housing 2, and then fixing the low-voltage module structure 9 to the low-voltage module bracket 4. The eighth step involves fixing the cooling water outlet nozzle 14, cooling water inlet nozzle 20, and low-voltage plug-in modules sequentially to the housing, and then connecting the internal low-voltage wiring harness. The ninth step involves installing the top cover 1 onto the housing 2, thus completing the motor controller structure assembly.

[0122] It should be noted that the above assembly process is only an example and does not limit the actual assembly process.

[0123] like Figure 21 As shown, taking the suspension motor control of the active suspension control system as an example, the motor controller structure provided in this application can receive real-time target torque requests, working mode requests, physical angle requests, and other related signals issued by the active suspension control system nodes through the vehicle bus. After real-time control processing by the various circuit modules inside the motor controller structure, it accurately sends out three-phase sine current to drive the motor to rotate, realizing the real-time output of the target torque to the demand system. The circuit system of this motor controller structure has multiple working modes, including normal working mode and passive damping working mode, which are described below.

[0124] In the normal operating mode of the motor controller structure, firstly, all external plug-ins of the motor controller structure are connected. Low-voltage and high-voltage power is supplied to the motor controller structure's circuit system via the active suspension control system nodes. Once the motor controller's circuit system receives the vehicle's low-voltage power, each low-voltage module begins operation, supplying high-voltage power to the motor controller's circuit system. The vehicle's DC+ / DC- input is then fed to the C-stage of the upper bridge power device and the E-stage of the lower bridge power device in the high-voltage power module. After receiving the target torque / speed / angle commands, the motor controller's circuit system enters normal operating mode. The internal low-voltage control module of the motor controller's circuit system processes the data in real time, sending a PWM signal that meets the requirements to the high-voltage drive module. This allows for real-time control of the G-stage of the high-voltage power module's power devices, generating the required U / V / W three-phase AC power to drive the motor. At this time, the internal water-cooling circuit of the motor controller structure removes the heat generated by the high-voltage power module during operation, preventing overheating of the motor controller system and subsequent performance degradation or malfunction. Finally, the motor outputs the required torque / speed / angle to the next-level demand system.

[0125] like Figure 22 As shown, press in passive damping mode. Figure 17 To carry out the work:

[0126] First, connect all external plugs to the motor controller. Then, through the active suspension control system node, supply low-voltage and high-voltage electricity to the motor controller. Once the motor controller supplies the vehicle's low-voltage electricity, each low-voltage module starts working and supplies the high-voltage electricity to the motor controller, inputting the vehicle's DC+ / DC- to the C-level of the upper axle power device and the E-level of the lower axle power device of the high-voltage power module.

[0127] Then, the motor controller receives the passive damping operating mode request and enters the passive damping operating mode. The low-voltage control module inside the motor controller processes the data in real time, controlling the switches of relevant internal power devices. First, it cuts off the high-voltage DC+ / DC- input from the vehicle to the motor controller, and then activates the switches of relevant power devices in the internal damping resistor module circuit, forming the passive damping mode operating circuit. Finally, during the motor reverse drag process, the back electromotive force generated is absorbed by the damping resistor module and provides real-time lateral damping force to the vehicle, improving the vehicle's lateral stability. This further illustrates that the lateral damping force can be matched to the actual vehicle through vehicle calibration by adjusting the damping resistor value. If the back electromotive force voltage generated by the motor reverse drag exceeds the vehicle bus DC+ / DC- voltage, the motor controller can charge the power battery pack by controlling the diodes of the power devices inside the motor controller that receive the high-voltage input from the vehicle, thus achieving energy recovery.

[0128] In one embodiment, a vehicle is also provided, the vehicle including the motor controller structure as described in any of the foregoing embodiments.

[0129] It should be understood that more details and descriptions of the vehicle embodiments, including implementation methods and technical effects, can be found in the description of the motor controller structure in the foregoing embodiments, and will not be repeated here.

[0130] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional units and modules is used as an example. In practical applications, the above functions can be assigned to different functional units and modules as needed, that is, the internal structure of the device can be divided into different functional units or modules to complete all or part of the functions described above.

[0131] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application 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. Such 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 application, and should all be included within the protection scope of this application.

Claims

1. A motor controller structure, characterized in that, include: Top cover; A housing, the housing including a surrounding wall, the surrounding wall being fixedly connected to the upper cover, and an installation cavity being formed between the housing and the upper cover; The circuit module structure includes a high-voltage module structure and a low-voltage module structure. A low-voltage module bracket is fixed to the mounting cavity. The low-voltage module structure is fixed on the low-voltage module bracket. The high-voltage module structure is fixed to the mounting cavity. The high-voltage module structure is located below the low-voltage module bracket. The high-voltage module structure and the low-voltage module structure are separated by the low-voltage module bracket.

2. The motor controller structure as described in claim 1, characterized in that, The circuit module structure also includes a conductive connection bus structure, and the high voltage module structure includes a high voltage drive module structure and a high voltage power module structure. Both the high-voltage drive module structure and the high-voltage power module structure are fixed in the mounting cavity, and the circuit modules in the high-voltage drive module structure and the high-voltage power module structure are respectively connected to the corresponding conductive connection points of the conductive connection bar structure.

3. The motor controller structure as described in claim 2, characterized in that, The motor controller structure also includes a first connecting row fixing bracket and a second connecting row fixing bracket; The first connecting bar fixing bracket and the second connecting bar fixing bracket are respectively fixed to the two ends of the mounting cavity in the first direction, and the two ends of the conductive connecting bar structure are respectively fixed to the first connecting bar fixing bracket and the second connecting bar fixing bracket.

4. The motor controller structure as described in claim 2, characterized in that, The low-voltage module support includes multiple low-voltage module structure mounting points, and the low-voltage module support is provided with a support reinforcing rib structure.

5. The motor controller structure as described in claim 1, characterized in that, The bottom wall of the housing is provided with an EMC module mounting structure, and the circuit module structure further includes an EMC module structure, which is fixed to the EMC module mounting structure.

6. The motor controller structure as described in any one of claims 1-5, characterized in that, The outer wall of the enclosure is provided with a cooling water outlet and a cooling water inlet. The bottom wall of the shell is provided with a cooling water passage. The outlet of the cooling water passage is connected to the cooling water outlet, and the inlet of the cooling water passage is connected to the cooling water inlet.

7. The motor controller structure as described in claim 6, characterized in that, The motor controller structure also includes a cooling water circuit sealing plate. A notch is provided on the outer wall of the bottom wall of the housing. The cooling water circuit is located in the notch. The cooling water circuit sealing plate is sealed to the notch.

8. The motor controller structure as described in any one of claims 1-5, characterized in that, The outer wall of the enclosure is provided with multiple high-voltage plug-in installation structures of different plug-in types.

9. The motor controller structure as described in claim 8, characterized in that, The enclosure includes a first side wall, a second side wall, a third side wall, and a fourth side wall. The first side wall, the second side wall, the third side wall, and the fourth side wall together form the enclosure. Multiple high-voltage plug-in installation structures are disposed on the outer wall surface of the same side wall.

10. The motor controller structure as described in claim 9, characterized in that, The outer walls of the other side walls in the enclosure that do not have the high-voltage plug-in installation structure are respectively provided with shell external installation structures.

11. The motor controller structure as described in claim 8, characterized in that, The high-voltage plug-in mounting structure includes a DC high-voltage plug-in mounting structure, a low-voltage plug-in mounting structure, and one or more motor high-voltage plug-in mounting structures.

12. The motor controller structure as described in claim 11, characterized in that, The high-voltage plug-in mounting structure also includes a damping resistor plug-in mounting structure, which is used to install the damping resistor plug-in module.

13. The motor controller structure according to any one of claims 1-5, characterized in that, The mounting cavity is provided with a pre-charged capacitor module mounting structure at one end in the second direction for mounting the pre-charged capacitor module.

14. The motor controller structure as described in any one of claims 1-5, characterized in that, The upper cover is provided with a cover reinforcement rib structure on the inner wall surface facing the shell.

15. A vehicle, characterized in that, The vehicle includes the motor controller structure as described in any one of claims 1-14.

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