New energy controller

Abstract

The utility model discloses a new energy controller, and relates to the technical field of controllers. Comprising a case, and a water cooling tank is arranged in the case. The control board, the power board and the IGBT module are in data signal connection in a plug-in mode, the IGBT module is cooled through circulating water cooling of the water cooling groove, then heat dissipation is indirectly conducted on the power board and the control board, the overall temperature of elements in a machine case can be reduced to be within the standard range, and therefore the service life of a product is prolonged; the heat dissipation efficiency of the IGBT module is further ensured, the arrangement of a water-cooling sealing ring prevents liquid in a water-cooling groove from leaking into the interior of the case, the case sealing ring is matched with an interface sealing ring, the interface and the case can be sealed with the upper cover plate at the same time, and the arrangement of an access hole facilitates wiring and maintenance operation. The maintenance cover plate and the cover plate sealing ring are used for sealing the maintenance opening, and the multiple sealing rings are arranged, so that the overall sealing performance of the product is greatly improved.

Description

Technical Field

[0001] This utility model relates to the field of controller technology, specifically a new energy controller. Background Technology

[0002] The new energy vehicle controller is used to control the high and low speed transitions of new energy vehicles and to change gears to change speed. However, existing new energy vehicle controllers still have the following shortcomings in use:

[0003] The three main components of a new energy controller—the IGBT, the power board, and the control board—generate a lot of heat when they are in operation. In particular, the IGBT generates even more heat, which often causes various problems due to overheating of the new energy controller, resulting in unsatisfactory performance. Summary of the Invention

[0004] To achieve the above objectives, this utility model provides the following technical solution: a new energy controller, including a chassis, a water-cooling tank inside the chassis, an IGBT module on top of the water-cooling tank, a plastic base located on one side of the water-cooling tank inside the chassis, a waterproof connector extending into the plastic base on one side of the chassis, a power board on top of the IGBT module, a control board on top of the power board, a top cover on top of the chassis, an inspection port corresponding to the plastic base inside the top cover, a water-cooling sealing ring between the water-cooling tank and the IGBT module, a chassis sealing ring between the chassis and the top cover, a cover sealing ring on top of the inspection port, and a capacitor inside the chassis.

[0005] As a preferred technical solution of this utility model, two water-cooling connectors connected to the inside of the water-cooling tank are provided on one side of the chassis. A sealing sleeve is provided on the water-cooling connector. A water-cooling sealing groove is provided on the top of the water-cooling tank. The water-cooling sealing ring is embedded in the inside of the water-cooling sealing groove.

[0006] As a preferred technical solution of this utility model, the bottom of the IGBT module is provided with a groove that engages with the top of the water-cooling sealing ring, and the bottom of the IGBT module is also provided with several heat-conducting fins with one end extending into the water-cooling tank. The top of the IGBT module is provided with several pins whose top ends are inserted into the bottom of the power board.

[0007] As a preferred embodiment of this utility model, the chassis is provided with a sheet metal base inside, the sheet metal base is provided with a through hole inside, the sheet metal base is located above the power board, and the top of the power board is provided with a plug that has a through hole at the top and is inserted into the bottom of the control board.

[0008] As a preferred technical solution of this utility model, two studs are symmetrically arranged inside the chassis, and the two ends of the capacitor are provided with connecting ears corresponding to the two studs. The connecting ears are fixed with the studs by screws. Two studs are provided at one end of the top of the sheet metal base, and the control board is fixed inside the sheet metal base by screws.

[0009] As a preferred technical solution of this utility model, the top of the upper cover is provided with a maintenance cover for blocking the inspection port, one end of the control board is provided with a bus interface, and one side of the chassis is provided with a clearance groove that fits into the bus interface.

[0010] As a preferred technical solution of this utility model, a chassis sealing groove is provided together on the top ring of the chassis and inside the clearance groove. An interface sealing ring is provided on the bottom side of one side of the chassis sealing ring. The inside of the interface sealing ring is fitted with the outside of the bus interface. The chassis sealing ring and the connector sealing ring are nested together inside the chassis sealing groove.

[0011] As a preferred embodiment of this utility model, one side of the plastic base is provided with at least one wiring groove, and the other side is provided with a copper busbar extending to the power board and control board. One side of the plastic base is provided with at least one magnetic ring, and the number of waterproof connectors is at least one. One end of the waterproof connector passes through the magnetic ring and extends into the interior of the wiring groove.

[0012] As a preferred embodiment of this utility model, a fixing plate is provided on one side of the chassis, a connecting plate is provided on the outside of the waterproof connector, the connecting plate and the fixing plate are fixed by screws, and at least one mounting base is provided on both sides of the chassis.

[0013] As a preferred technical solution of this utility model, a vent valve is also provided on the top side of the chassis, and several plastic parts are respectively located on both sides of the IGBT module inside the chassis.

[0014] Compared with the prior art, this utility model provides a new energy controller with the following advantages:

[0015] This new energy controller uses a plug-and-play connection between the control board, power board, and IGBT modules for data signal transmission. A water-cooling tank circulates water to cool the IGBT modules, indirectly dissipating heat from the power board and control board. This ensures that the overall temperature of the components inside the chassis remains within the standard range, thus improving product lifespan. The heat-conducting fins further guarantee the heat dissipation efficiency of the IGBT modules. The water-cooling sealing ring prevents liquid leakage from the cooling tank into the chassis. The chassis sealing ring, in conjunction with the interface sealing ring, simultaneously seals the interfaces and the connection between the chassis and the top cover. The access port facilitates wiring and maintenance operations. The access port is sealed by a maintenance cover and its sealing ring. The multiple sealing rings significantly enhance the overall airtightness of the product. Attached Figure Description

[0016] Figure 1 This is an exploded view of the structure of a new energy controller proposed in this utility model;

[0017] Figure 2 This is a schematic diagram of the plastic base structure of a new energy controller proposed in this utility model;

[0018] Figure 3 This is a schematic diagram of the IGBT module structure of a new energy controller proposed in this utility model;

[0019] Figure 4 This is a schematic diagram of the control board structure of a new energy controller proposed in this utility model;

[0020] Figure 5 This is a schematic diagram of the chassis structure of a new energy controller proposed in this utility model.

[0021] In the diagram: 1. Chassis; 101. Water-cooling tank; 102. Water-cooling sealing groove; 103. Water-cooling connector; 1031. Sealing sleeve; 104. Stud 1; 105. Clearance groove; 106. Chassis sealing groove; 107. Mounting base; 108. Fixing plate; 109. Vent valve; 2. Plastic base; 201. Wiring groove; 202. Magnetic ring; 203. Copper busbar; 204. Connecting strip; 205. Fixing hole; 206. Screw; 3. Waterproof connector; 301. 4. IGBT module; 401. Pin; 402. Heat-conducting fins; 5. Power board; 501. Plug; 6. Sheet metal base; 601. Through hole; 602. Stud II; 7. Control board; 701. Bus interface; 8. Top cover; 801. Inspection port; 9. Maintenance cover; 10. Water-cooling sealing ring; 11. Chassis sealing ring; 1101. Interface sealing ring; 12. Cover sealing ring; 13. Plastic parts; 14. Capacitor; 1401. Connecting lug. Detailed Implementation

[0022] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0023] Please see Figure 1-5 A new energy controller includes a chassis 1, inside which a water-cooling tank 101 is provided, and an IGBT module 4 is provided on top of the water-cooling tank 101. A plastic base 2 is located on one side of the water-cooling tank 101 inside the chassis 1. A waterproof connector 3 extending into the plastic base 2 is provided on one side of the chassis 1. A power board 5 is provided on top of the IGBT module 4, and a control board 7 is also provided on top of the power board 5. A top cover 8 is provided on top of the chassis 1, and an inspection port 801 corresponding to the plastic base 2 is provided inside the top cover 8. A water-cooling sealing ring 10 is provided between the water-cooling tank 101 and the IGBT module 4. A chassis sealing ring 11 is provided between the chassis 1 and the top cover 8. A cover sealing ring 12 is provided on top of the inspection port 801. A capacitor 14 is also provided inside the chassis 1.

[0024] The control board 7, power board 5, and IGBT module 4 are connected via plug-in interface for data signals. The IGBT module 4 is cooled by circulating water through the water cooling tank 101, which in turn indirectly dissipates heat from the power board 5 and control board 7. This ensures that the overall temperature of the components inside the chassis 1 can be reduced to within the standard range, thereby improving the product's lifespan. The design of the heat-conducting fins 402 further ensures the heat dissipation efficiency of the IGBT module 4, solving the problems of slow heat dissipation and high temperature, and reducing the occurrence of failures due to high heat.

[0025] Most components inside the chassis are fixed with 206 screws, making disassembly easier, greatly reducing assembly difficulty, shortening assembly time, reducing production cycle, resulting in low defect rate and high yield.

[0026] The chassis 1 and water cooling tank 101 are made of a large piece of aluminum, which greatly increases the heat dissipation area and heat dissipation efficiency.

[0027] The structural design is compatible with multiple product models, reducing production difficulties.

[0028] The water-cooling sealing ring 10 prevents liquid inside the water-cooling tank 101 from leaking into the chassis 1. The chassis sealing ring 11, together with the interface sealing ring 1101, can simultaneously seal the interface and the connection between the chassis 1 and the upper cover plate 8. The access port 801 facilitates wiring and maintenance operations. The access port 801 is sealed by the maintenance cover plate 9 and the cover plate sealing ring 12. The multiple sealing rings greatly improve the overall waterproof and dustproof performance of the product.

[0029] As a specific technical solution of this embodiment, two water-cooling connectors 103 connected to the inside of the water-cooling tank 101 are provided on one side of the chassis 1. A sealing sleeve 1031 is provided on the water-cooling connector 103. A water-cooling sealing groove 102 is provided on the top of the water-cooling tank 101. The water-cooling sealing ring 10 is embedded in the inside of the water-cooling sealing groove 102.

[0030] In this embodiment, two water-cooling connectors 103 are used for the entry and exit of cooling water, respectively, so that the cooling water circulates inside the water-cooling tank 101 to dissipate heat from the IGBT module 4. The water-cooling tank 101 and the chassis 1 are both made of aluminum, which can quickly dissipate heat and further ensure the heat dissipation efficiency of the IGBT module 4, power board 5 and control board 7, keeping the product at a normal temperature and reducing various abnormal failures caused by excessive temperature. The sealing sleeve 1031 on the water-cooling connector 103 can ensure the sealing of the pipe connection and avoid leakage.

[0031] As a specific technical solution in this embodiment, the bottom of the IGBT module 4 is provided with a groove that engages with the top of the water-cooling sealing ring 10, and the bottom of the IGBT module 4 is also provided with a number of heat-conducting fins 402 with one end extending into the water-cooling tank 101. The top of the IGBT module 4 is provided with a number of pins 401 whose top ends are inserted into the bottom of the power board 5.

[0032] In this embodiment, the arrangement of multiple heat-conducting fins 402, in conjunction with water cooling circulation, further ensures the heat dissipation efficiency of the IGBT module 4. The IGBT module 4 and the power board 5 are connected by plug-in pins 401. The internal structure is neat, simple, and easy to assemble and disassemble. The bottom of the IGBT module 4 and the top of the water cooling tank 101 are respectively provided with slots that nest with the top and bottom of the water cooling sealing ring 10, further ensuring the sealing of the water cooling tank 101 and preventing the circulating water from overflowing and causing leakage problems.

[0033] As a specific technical solution in this embodiment, the chassis 1 is provided with a sheet metal base 6 inside, the sheet metal base 6 is provided with a through hole 601 inside, the sheet metal base 6 is located above the power board 5, and the top of the power board 5 is provided with a plug 501 that is inserted into the through hole 601 at the top and connected to the bottom of the control board 7.

[0034] In this embodiment, the bottom of the control board 7 is provided with a socket that is plugged into the plug 501. The power board 5 and the control board 7 are connected and transmit signals by plugging into the socket. The product has stable performance, simple and neat appearance. The sheet metal base 6 is used to fix the control board 7.

[0035] As a specific technical solution of this embodiment, two studs 104 are symmetrically arranged inside the chassis 1. The two ends of the capacitor 14 are provided with connecting ears 1401 corresponding to the two studs 104 respectively. The connecting ears 1401 are fixed with the studs 104 by screws 206. Two studs 602 are provided at one end of the top of the sheet metal base 6. The control board 7 is fixed inside the sheet metal base 6 by the studs 602 and screws 206.

[0036] In this embodiment, capacitor 14 is fixed inside the chassis 1 by connecting lug 1401 and stud 104 with screw 206. Capacitor 14 is located on the side of water cooling tank 101 away from plastic base 2. Screw 206 on one side of sheet metal base 6 is fixed to the top of capacitor 14. Control board 7 is fixed to sheet metal base 6 by stud 202 and screw 206. After control board 7 is fixed to sheet metal base 6, it can be plugged and connected to power board 5. The assembly process is simple, quick and more stable. Capacitor 14 is used to supply AC power to various components in series to form a circuit.

[0037] As a specific technical solution in this embodiment, the top of the upper cover plate 8 is provided with a maintenance cover plate 9 for blocking the inspection port 801, one end of the control board 7 is provided with a bus interface 701, and one side of the chassis 1 is provided with a clearance groove 105 that is fitted with the bus interface 701.

[0038] In this embodiment, the clearance groove 105 is used to place the bus interface 701. The maintenance cover 9 is fixed to the top of the upper cover 8 by the locking screw 206. After the maintenance cover 9 is locked, the maintenance cover 9 presses the cover sealing ring 12 to achieve the sealing of the inspection port 801.

[0039] As a specific technical solution of this embodiment, a chassis sealing groove 106 is provided on the top ring of the chassis 1 and inside the clearance groove 105. An interface sealing ring 1101 is provided on the bottom side of one side of the chassis sealing ring 11. The inside of the interface sealing ring 1101 is connected to the outside of the bus interface 701. The chassis sealing ring 11 and the connector sealing ring are nested inside the chassis sealing groove 106.

[0040] In this embodiment, an interface sealing ring 1101 is provided on one bottom side of the chassis sealing ring 11. This design makes the combination of the chassis sealing ring 11 and the interface sealing ring 1101 more perfectly fit the chassis sealing groove 106, effectively sealing the bus interface 701 and the connection between the chassis 1 and the upper cover plate 8, preventing water leakage and making it safer to use.

[0041] As a specific technical solution of this embodiment, the plastic base 2 is provided with a wiring groove 201 on one side and a copper busbar 203 extending to the power board 5 and the control board 7 on the other side. The plastic base 2 is provided with a magnetic ring 202 on one side and a waterproof connector 3 is provided with a number of at least one. One end of the waterproof connector 3 passes through the magnetic ring 202 and extends into the interior of the wiring groove 201.

[0042] In this embodiment, the wire passes through the waterproof connector 3 into the wiring groove 201 and is connected to the terminal inside the plastic base 2 and fixed by the locking screw 206. The wiring operation can be completed through the inspection port 801. A number of fixing holes 205 are provided on one side of the plastic base 2. A connecting strip 204 extending to the fixing hole 205 is provided on one side of the magnetic ring 202. The connecting strip 204 is fixed to the fixing hole 205 by the locking screw 206, realizing the connection between the magnetic ring 202 and the plastic base 2.

[0043] As a specific technical solution of this embodiment, a fixing plate 108 is provided on one side of the chassis 1, and a connecting plate 301 is provided on the outside of the waterproof connector 3. The connecting plate 301 and the fixing plate 108 are fixed by screws 206. At least one mounting base 107 is provided on both sides of the chassis 1.

[0044] In this embodiment, the chassis 1 can be installed on the car via the mounting base 107, and the waterproof connector 3 is fixed to the fixing plate 108 via the connecting plate 301 and the screw 206. The wires pass through the waterproof connector 3 and enter the interior of the chassis 1.

[0045] As a specific technical solution of this embodiment, a vent valve 109 is also provided on the top side of the chassis 1, and a number of plastic parts 13 are respectively located on both sides of the IGBT module 4 inside the chassis 1.

[0046] In this embodiment, the IGBT module 4 has multiple copper terminals on both sides, one end of which extends to the plastic part 13 and is locked with screws 206. This can achieve insulation and prevent signal interference with other components. The IGBT module 4 is connected to the wires and capacitor 14 through the copper terminals. The plastic part 13 is fixed inside the chassis 1. The vent valve 109 has waterproof and breathable functions.

[0047] In summary, this new energy controller uses a plug-and-play connection between the control board 7, power board 5, and IGBT module 4 for data signal connection. The IGBT module 4 is cooled by circulating water in the water-cooling tank 101, which indirectly dissipates heat from the power board 5 and control board 7. This ensures that the overall temperature of the components inside the chassis 1 is reduced to within the standard range, thereby improving the product's lifespan. The design of the heat-conducting fins 402 further guarantees the heat dissipation efficiency of the IGBT module 4. The water-cooling sealing ring 10 prevents liquid leakage from the water-cooling tank 101 into the chassis 1. The chassis sealing ring 11, in conjunction with the interface sealing ring 1101, can simultaneously seal the interface and the connection between the chassis 1 and the top cover 8. The inspection port 801 facilitates wiring and maintenance operations. The inspection port 801 is sealed by the maintenance cover 9 and the cover sealing ring 12. The multiple sealing rings greatly enhance the overall waterproof and dustproof performance of the product.

[0048] It should be noted that, in this document, terms such as "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[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 new energy controller, comprising a chassis (1), characterized in that: The chassis (1) is equipped with a water cooling tank (101) inside, and an IGBT module (4) is installed on top of the water cooling tank (101). A plastic base (2) is located on one side of the water cooling tank (101) inside the chassis (1). A waterproof connector (3) with one end extending into the plastic base (2) is installed on one side of the chassis (1). A power board (5) is installed on top of the IGBT module (4), and a control board (7) is also installed on top of the power board (5). The top of the chassis (1) is provided with a top cover plate (8), and the inside of the top cover plate (8) is provided with an inspection port (801) corresponding to the plastic base (2). A water-cooling sealing ring (10) is provided between the water-cooling tank (101) and the IGBT module (4). A chassis sealing ring (11) is provided between the chassis (1) and the top cover plate (8). A cover plate sealing ring (12) is provided on the top of the inspection port (801). A capacitor (14) is also provided inside the chassis (1).

2. A new energy controller according to claim 1, characterized in that: Two water-cooling connectors (103) are provided on one side of the chassis (1) and are connected to the inside of the water-cooling tank (101). A sealing sleeve (1031) is provided on the water-cooling connector (103). A water-cooling sealing groove (102) is provided on the top of the water-cooling tank (101). The water-cooling sealing ring (10) is embedded in the inside of the water-cooling sealing groove (102).

3. A new energy controller according to claim 1, characterized in that: The bottom of the IGBT module (4) is provided with a groove that engages with the top of the water-cooled sealing ring (10), and the bottom of the IGBT module (4) is also provided with several heat-conducting fins (402) with one end extending into the water-cooled tank (101). The top of the IGBT module (4) is provided with several pins (401) whose top ends are inserted into the bottom of the power board (5).

4. A new energy controller according to claim 1, characterized in that: The chassis (1) is provided with a sheet metal base (6) inside, and a through hole (601) is provided inside the sheet metal base (6). The sheet metal base (6) is located above the power board (5). The top of the power board (5) is provided with a top through hole (601) and a plug (501) that is plugged into the bottom of the control board (7).

5. A new energy controller according to claim 4, characterized in that: The chassis (1) is symmetrically provided with two studs (104) inside. The capacitor (14) is provided with connecting ears (1401) at both ends, which are respectively corresponding to the two studs (104). The connecting ears (1401) are fixed with the studs (104) by screws (206). The top end of the sheet metal base (6) is provided with two studs (602). The control board (7) is fixed to the inside of the sheet metal base (6) by the studs (602) and screws (206).

6. A new energy controller according to claim 1, characterized in that: The top of the upper cover plate (8) is provided with a maintenance cover plate (9) for covering the inspection port (801), and a bus interface (701) is provided at the bottom of one end of the control board (7). A clearance groove (105) is provided on one side of the chassis (1) to be fitted with the bus interface (701).

7. A new energy controller according to claim 1, characterized in that: The top ring of the chassis (1) and the interior of the clearance groove (105) are provided with a chassis sealing groove (106). An interface sealing ring (1101) is provided on the bottom side of the chassis sealing ring (11). The interior of the interface sealing ring (1101) is connected to the exterior of the bus interface (701). The chassis sealing ring (11) and the connector sealing ring are nested together inside the chassis sealing groove (106).

8. A new energy controller according to claim 1, characterized in that: The plastic base (2) has at least one wiring groove (201) on one side and a copper busbar (203) on the other side that extends to the power board (5) and the control board (7). The plastic base (2) has at least one magnetic ring (202) on one side and at least one waterproof connector (3). One end of the waterproof connector (3) passes through the magnetic ring (202) and extends into the inside of the wiring groove (201).

9. A new energy controller according to claim 1, characterized in that: A fixing plate (108) is provided on one side of the chassis (1), and a connecting plate (301) is provided on the outside of the waterproof connector (3). The connecting plate (301) and the fixing plate (108) are fixed by screws (206). At least one mounting seat (107) is provided on both sides of the chassis (1).

10. A new energy controller according to claim 1, characterized in that: A vent valve (109) is also provided on the top of one side of the chassis (1), and several plastic parts (13) are respectively located on both sides of the IGBT module (4) inside the chassis (1).

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