Motor controller and vehicle thereof

Abstract

The utility model discloses a motor controller and a vehicle thereof, the motor controller comprises a controller shell with an accommodating chamber, and an OBC, a PTC control panel, a PCBA driving control panel, an IGBT and a heat dissipation water channel are integrated in the accommodating chamber; the PTC control board is connected with the PCBA driving control board through pin header welding; the heat dissipation water channel is communicated with an internal water channel of the OBC, and cooling liquid of the heat dissipation water channel is in direct contact with a pin assembly of the IGBT; the controller shell is provided with a compressor interface and a PTC interface. The OBC is placed in the motor controller, so that the overall appearance size can be reduced; the PTC control board and the PCBA drive are connected by adopting a pin header scheme, so that the use of a switching wire harness is reduced, the utilization rate of space is increased, and the cost is effectively reduced; meanwhile, the pin structure is placed in cooling liquid of a heat dissipation water channel of the motor controller, water-cooling circulation heat dissipation is achieved, and the heat dissipation water channel is connected with an internal water channel of the OBC, so that heat dissipation of the OBC is achieved.

Description

Technical Field

[0001] This utility model relates to the field of electric drive technology for new energy vehicles, specifically to a motor controller and its vehicle. Background Technology

[0002] In the current market, all-in-one controllers are generally designed using a structural integration approach. While this design method can integrate multiple functional modules into a single device, it also has some significant drawbacks and challenges.

[0003] First, the external dimensions of the space are large and the internal space utilization of the controller is not high.

[0004] Secondly, in terms of cost control, structural integration solutions often mean higher manufacturing complexity and production costs.

[0005] It is evident that designing an integrated, compact, and lightweight motor controller is an urgent industry problem that needs to be solved. Utility Model Content

[0006] In a first aspect, to solve the above-mentioned technical problems, the present invention provides a motor controller, comprising a controller housing having a receiving chamber, wherein:

[0007] The housing integrates an OBC, a PTC control board, a PCBA drive control board, an IGBT, and a cooling channel; the PTC control board and the PCBA drive control board are connected by pin header soldering; the cooling channel is connected to the internal water channel of the OBC, and the coolant in the cooling channel directly contacts the pinfin assembly of the IGBT.

[0008] The controller housing is equipped with a compressor interface and a PTC interface.

[0009] Furthermore, the bottom of the controller housing is provided with a water inlet and a water outlet, a first water inlet is provided in the housing and located at the position of the OBC, and a second water inlet is provided in the housing and located at the position of the IGBT; the coolant of the heat dissipation channel flows through the water inlet into the first water inlet to the internal water channel of the OBC, and flows through the pinfin assembly of the IGBT through the second water inlet and then flows into the motor through the water outlet.

[0010] Furthermore, the controller housing sidewall is also provided with a low-voltage plug, a slow-charging plug, and a fast-charging harness interface; wherein, the low-voltage plug is connected to a 12V power supply; and the slow-charging plug is connected to the OBC.

[0011] Furthermore, a filter component is provided on the side of the receiving chamber near the fast charging harness interface; current is transmitted to the filter component through the fast charging harness interface; the path from the filter component to the battery pack is provided with a positive copper busbar, a relay, a negative copper busbar, a positive adapter copper busbar, a negative adapter copper busbar, and a battery cable fixing seat.

[0012] Furthermore, the bottom of the controller housing is also provided with a DC high-voltage bus interface. The power battery current is transmitted to the battery cable fixing base through the DC high-voltage bus interface, and then transmitted to the film capacitor for storage by the positive and negative transfer copper busbars.

[0013] Furthermore, the compressor interface and the PTC interface draw power from the battery pack via a wiring harness, and the wiring harness is fixed to the wiring harness mounting bracket via a first fuse and a second fuse.

[0014] Furthermore, the OBC is connected to the third fuse of the fuse holder via the OBC wiring harness, and a wire groove is provided on the bottom wall of the controller housing to fix the OBC wiring harness.

[0015] Furthermore, the controller housing is also equipped with a controller cover plate, and a controller junction box cover plate is also provided on one side of the controller cover plate. The controller junction box cover plate is fixed to the controller housing by bolts.

[0016] Furthermore, a vent valve is provided on the side wall of the controller housing to balance the pressure inside and outside the controller housing.

[0017] A second aspect of this utility model is to provide a vehicle including the aforementioned motor controller.

[0018] Compared with the prior art, the present invention has the following beneficial effects:

[0019] This invention reduces the overall size by placing the OBC inside the motor controller; it reduces the use of adapter harnesses by connecting the PTC control board and PCBA driver using a pin header scheme, which increases space utilization and effectively reduces costs; at the same time, placing the pinfin structure in the cooling water channel of the motor controller enables water-cooled circulation and heat dissipation, and this cooling water channel is connected to the internal water channel of the OBC to achieve OBC heat dissipation, which can effectively improve the overall reliability and system stability of the motor controller. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the external structure of the motor controller disclosed in an embodiment of the present utility model;

[0021] Figure 2This is an isometric view of the motor controller disclosed in an embodiment of the present utility model;

[0022] Figure 3 This is a schematic diagram of the internal structure of the motor controller disclosed in an embodiment of the present utility model, showing a partial structural diagram with the PTC control board and PCBA drive control board removed;

[0023] Figure 4 This is a schematic diagram of the internal structure of the motor controller disclosed in an embodiment of the present utility model, showing a partial structural schematic diagram of the removed fuse and fuse holder;

[0024] Figure 5 This is a schematic diagram of the bottom structure of the motor controller disclosed in an embodiment of the present utility model;

[0025] Figure 6 This is a schematic diagram of the internal structure of the motor controller disclosed in an embodiment of the present utility model, showing a structural schematic diagram with IGBTs and film capacitors retained;

[0026] Figure 7 This is a schematic diagram of the internal structure of the motor controller disclosed in an embodiment of this utility model.

[0027] In the picture:

[0028] 1. Controller housing; 2. Controller cover; 3. Controller junction box cover;

[0029] 1a1, OBC; 1a2, PTC control board; 1a3, PCBA drive control board; 1a4, filter assembly; 1a5, positive copper busbar; 1a6, relay; 1a7, negative copper busbar; 1a8, positive adapter copper busbar; 1a9, negative adapter copper busbar; 1a10, battery cable holder; 1a11, film capacitor; 1a12, fuse holder; 1a13, first fuse; 1a14, second fuse; 1a15, third fuse; 1a16, first water inlet; 1a17, second water inlet; 1a18, U-phase copper busbar; 1a19, V-phase copper busbar; 1a20, W-phase copper busbar; 1a21, IGBT; 1a22, wire harness holder;

[0030] 1b1, Water inlet; 1b2, Water outlet; 1b3, DC high-voltage bus interface;

[0031] 1c1, Compressor interface; 1c2, PTC interface; 1c3, Low-pressure connector; 1c4, Slow-charge connector; 1c5, Fast-charge harness interface; 1c6, Vent valve. Detailed Implementation

[0032] To make the technical solutions and effects of this utility model clearer, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings in the embodiments. Obviously, the described embodiments are some embodiments of this utility model, but not all embodiments.

[0033] The first aspect of this invention aims to provide an integrated, compact, and lightweight motor controller. By integrating the power supply function into the motor controller, the overall weight of the motor controller is reduced, its physical dimensions are reduced, and costs are lowered.

[0034] It should be noted that this utility model provides a structural design scheme for a motor controller that is matched with an 11KW power supply.

[0035] First, the overall external structure of the motor controller disclosed in this embodiment will be described.

[0036] Please see Figure 1 The motor controller includes a controller housing 1 with a housing, a controller cover 2, and a controller junction box cover 3 on one side of the controller cover 2. The controller junction box cover 3 is fixed to the controller housing 1 by bolts. Two vent valves 1c6 are provided on the side wall of the controller housing 1 to balance the internal and external pressure of the controller housing 1, preventing seal damage or component deformation, and preventing moisture and dust from entering, thus protecting the internal components.

[0037] Next, the external interface of the motor controller disclosed in this embodiment will be described.

[0038] Please see Figure 2 The controller housing 1 has a compressor interface 1c1 and a PTC interface 1c2 on its side wall. Both the compressor interface 1c1 and the PTC interface 1c2 are external connector ports, and both external connector ports are fixed to the controller housing 1 by bolts.

[0039] The controller housing 1 also has a low-voltage plug 1c3, a slow-charging plug 1c4, and a fast-charging harness interface 1c5 on its side wall. The low-voltage plug 1c3 is connected to a 12V power supply for supplying 12V power and for communicating with other controllers; the slow-charging plug 1c4 is externally connected to the vehicle's charging port and internally connected to the OBC 1a1.

[0040] Furthermore, the bottom of the motor controller disclosed in this embodiment will be described.

[0041] Please see Figure 5 The bottom of the controller housing 1 is provided with a water inlet 1b1, a water outlet 1b2, and a DC high-voltage bus interface 1b3.

[0042] Finally, the structural layout of the housing of the motor controller disclosed in this embodiment will be described.

[0043] Please see Figure 3-4 and Figure 6-7 The housing 1 of the controller integrates an OBC 1a1, a PTC control board 1a2, a PCBA drive control board 1a3, an IGBT 1a21, and a heat dissipation channel.

[0044] The PTC control board 1a2 and PCBA drive control board 1a3 are designed separately and connected by pin header soldering, which reduces the installation space and volume and effectively reduces the cost of the product.

[0045] The cooling water channel connects to the internal water channel of OBC 1a1, and the coolant in the cooling water channel directly contacts the pinfin assembly of IGBT 1a21. A first water inlet 1a16 is provided in the housing and located at the position of OBC 1a1; a second water inlet 1a17 is provided in the housing and located at the position of IGBT 1a21. The coolant in the cooling water channel flows into the first water inlet 1a16 through the water inlet 1b1 and into the internal water channel of OBC 1a1. After cooling and reducing the temperature of OBC 1a1, it flows again through the second water inlet 1a17 to cool and reduce the temperature of the pinfin assembly of IGBT 1a21, and then flows into the motor through the water outlet 1b2, realizing the water circulation of cooling water.

[0046] A filter component 1a4 is installed on the side of the housing near the fast charging harness interface 1c5. The current is transmitted to the filter component 1a4 through the fast charging harness interface 1c5 for filtering. By filtering out noise and spurious signals, the waveform of the circuit is made more stable, ensuring the reliability of the current.

[0047] The path from the current filter component 1a4 to the battery pack is sequentially provided with a positive copper busbar 1a5, a relay 1a6, a negative copper busbar 1a7, a positive adapter copper busbar 1a8, a negative adapter copper busbar 1a9, and a battery cable fixing seat 1a10.

[0048] The filtered current passes through the positive copper busbar 1a5, relay 1a6, and negative copper busbar 1a7, then through the positive transfer copper busbar 1a8 and negative transfer copper busbar 1a9, and finally flows into the battery pack for storage through the positive and negative terminals of the battery cable holder 1a10.

[0049] The compressor interface 1c1 and the PTC interface 1c2 draw power from the battery pack through the wiring harness. The wiring harness is fixed to the wiring harness fixing base 1a22 via the first fuse 1a13 and the second fuse 1a14 of the fuse fixing base 1a12.

[0050] OBC 1a1 is connected to the third fuse 1a15 of fuse holder 1a12 via OBC wiring harness. A wire groove is provided on the bottom wall of controller housing 1 to fix the OBC wiring harness. Its current flows through positive terminal adapter copper busbar 1a8 and negative terminal adapter copper busbar 1a9, and finally flows into the battery pack for storage through the positive and negative terminals of battery cable holder 1a10.

[0051] The power battery current is transmitted to the battery cable mounting base 1a10 through the DC high voltage bus interface 1b3. There is a filter component in the battery cable mounting base 1a10 to filter the output current. By filtering out noise and spurious signals, the stability and reliability of the current are ensured.

[0052] The filtered current is transmitted to the film capacitor 1a11 for storage through the positive terminal transfer copper busbar 1a8 and the negative terminal transfer copper busbar 1a9. The current passing through the film capacitor 1a11 is relatively more stable and reliable, which can prevent voltage overshoot and instantaneous voltage from affecting the IGBT 1a21.

[0053] After passing through IGBT 1a21, the DC power can be directly converted into three-phase AC power for the motor. The AC power is then transmitted to the motor through the U-phase copper busbar 1a18, V-phase copper busbar 1a19, and W-phase copper busbar 1a20 on the three-phase mounting base, thus realizing the conversion of electrical energy and mechanical energy.

[0054] This embodiment provides a controller design layout for a new energy passenger vehicle with a built-in 11kW power supply, offering a technical reference for the multi-functional innovation of motor controllers. Its structure is compact, its layout is reasonable, and its current flow is clear and well-defined.

[0055] A second aspect of this utility model is intended to protect a vehicle that includes the aforementioned motor controller.

[0056] 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 motor controller, characterized in that, Includes a controller housing (1) with a receiving chamber, wherein: The housing integrates an OBC (1a1), a PTC control board (1a2), a PCBA drive control board (1a3), an IGBT (1a21), and a cooling channel; the PTC control board (1a2) and the PCBA drive control board (1a3) are connected by pin header soldering; the cooling channel is connected to the internal water channel of the OBC (1a1), and the coolant in the cooling channel directly contacts the pinfin assembly of the IGBT (1a21); The controller housing (1) is provided with a compressor interface (1c1) and a PTC interface (1c2).

2. The motor controller according to claim 1, characterized in that, The bottom of the controller housing (1) is provided with a water inlet (1b1) and a water outlet (1b2). A first water inlet (1a16) is provided in the housing and located at the position of the OBC (1a1). A second water inlet (1a17) is provided in the housing and located at the position of the IGBT (1a21). The coolant of the heat dissipation channel flows through the water inlet (1b1) into the first water inlet (1a16) to the internal water channel of the OBC (1a1), and flows through the second water inlet (1a17) through the pinfin assembly of the IGBT (1a21) and then into the motor through the water outlet (1b2).

3. The motor controller according to claim 1, characterized in that, The controller housing (1) is also provided with a low-voltage plug (1c3), a slow-charging plug (1c4) and a fast-charging harness interface (1c5) on its side wall; wherein, the low-voltage plug (1c3) is connected to a 12V power supply; the slow-charging plug (1c4) is connected to the OBC (1a1).

4. The motor controller according to claim 3, characterized in that, A filter assembly (1a4) is provided on the side of the housing near the fast charging harness interface (1c5); current is transmitted to the filter assembly (1a4) through the fast charging harness interface (1c5); the path from the filter assembly (1a4) to the battery pack is provided with a positive copper busbar (1a5), a relay (1a6), a negative copper busbar (1a7), a positive adapter copper busbar (1a8), a negative adapter copper busbar (1a9), and a battery cable fixing seat (1a10).

5. The motor controller according to claim 4, characterized in that, The bottom of the controller housing (1) is also provided with a DC high voltage bus interface (1b3). The power battery current is transmitted through the DC high voltage bus interface (1b3) to the battery cable fixing seat (1a10), and then transmitted through the positive terminal adapter copper bus (1a8) and the negative terminal adapter copper bus (1a9) to the film capacitor (1a11) for storage.

6. The motor controller according to claim 1, characterized in that, The compressor interface (1c1) and the PTC interface (1c2) draw power from the battery pack via a wiring harness. The wiring harness is fixed to the wiring harness fixing base (1a22) via the first fuse (1a13) and the second fuse (1a14) ​​of the fuse fixing base (1a12).

7. The motor controller according to claim 6, characterized in that, The OBC (1a1) is connected to the third fuse (1a15) of the fuse holder (1a12) via the OBC wiring harness, and the bottom wall of the controller housing (1) is provided with a wire groove to fix the OBC wiring harness.

8. The motor controller according to claim 1, characterized in that, The controller housing (1) is also equipped with a controller cover plate (2), and a controller junction box cover plate (3) is also provided on one side of the controller cover plate (2). The controller junction box cover plate (3) is fixed to the controller housing (1) by bolts.

9. The motor controller according to claim 1 or 8, characterized in that, The controller housing (1) is also provided with a vent valve (1c6) on its side wall to balance the pressure inside and outside the controller housing (1).

10. A vehicle, characterized in that, Including the motor controller as described in any one of claims 1-9.

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