Power module assembly and controller

Abstract

The utility model discloses a power module assembly and a controller, the power module assembly comprises a circuit board, a power module and a current sensor, and the circuit board comprises a driving part and a control part which are distributed in parallel; the power module is connected to one side of the circuit board and is arranged corresponding to the driving part; the current sensor is connected to the side, provided with the power module, of the circuit board, the current sensor is arranged corresponding to the control part, and the current sensor is fixedly connected with the power module. According to the scheme, the system has relatively high integration level and reliability.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of new energy vehicles, in particular to a power module assembly and a controller. BACKGROUND

[0002] New energy vehicles have increasingly high requirements for power density, cost, weight and reliability of electric control, and the arrangement integration and reliability of components inside the controller are particularly crucial.

[0003] The controller in the prior art includes a circuit board, a power module and a current sensor, wherein the current sensor is used to detect three-phase current, and the current sensor is arranged as a single component in the controller, which has a large number of components, low assembly efficiency and low integration. CONTENT OF THE UTILITY MODEL

[0004] The present application mainly solves the technical problem of providing a power module assembly and a controller with high integration and reliability.

[0005] To solve the above technical problem, one technical solution adopted by the present application is to provide a power module assembly, comprising a circuit board, a power module and a current sensor, wherein the circuit board comprises a driving part and a control part arranged side by side; the power module is connected to one side of the circuit board, and the power module is arranged corresponding to the driving part; the current sensor is connected to the side of the circuit board where the power module is arranged, and the current sensor is arranged corresponding to the control part, and the current sensor is fixedly connected with the power module.

[0006] Preferably, one end of the power module close to the current sensor comprises a three-phase output end, and one end of the current sensor close to the power module comprises a three-phase connecting end, and the three-phase output end is fixedly connected with the three-phase connecting end.

[0007] Preferably, the power module assembly further comprises a first fixing bolt, a screw hole is arranged on the three-phase output end, a through hole is arranged on the three-phase connecting end, and the first fixing bolt passes through the through hole and is threadedly connected with the screw hole.

[0008] Preferably, the three-phase connecting end is arranged on the side of the three-phase output end facing the circuit board, an avoiding hole is arranged on the circuit board, and the three-phase connecting end is located in the avoiding hole.

[0009] Preferably, a shielding layer is arranged on the side of the control part facing the current sensor.

[0010] Preferably, the current sensor further comprises a current detection part, a support sealing part, the current detection part is connected between the three-phase connection end and the support sealing part, the support sealing part is provided with a motor connection end at one end away from the current detection part, the motor connection end extends to the side away from the circuit board, the support sealing part is provided with a sealing groove, the sealing groove is arranged around the motor connection end, and the sealing groove is provided with a sealing ring.

[0011] Preferably, the side of the current detection part facing the circuit board is provided with a sensor pin, and the sensor pin is welded or crimped with the circuit board.

[0012] Preferably, the side of the current detection part facing the circuit board is further provided with a sensor support column, the sensor support column is provided with a mounting hole, the power module assembly further comprises a second fixing bolt, the second fixing bolt passes through the circuit board and is threadedly connected with the mounting hole, and the sensor support column abuts against the side of the circuit board facing the current sensor.

[0013] Preferably, the power module assembly further comprises a shell, the shell is arranged on the side of the power module and the current sensor away from the circuit board, and the shell is fixedly connected with the power module and the current sensor.

[0014] To solve the above technical problems, another technical scheme adopted by the present application is to provide a controller comprising the power module assembly of any one of the embodiments.

[0015] The power module assembly provided by the present application has the advantages that, different from the prior art, the power module assembly integrates the circuit board, the current sensor and the power module, the circuit board is arranged at the uppermost layer, the current sensor and the power module are arranged side by side below the circuit board and correspond to the corresponding parts of the circuit board respectively, the layout space is fully utilized, the occupied space of the power module assembly in the thickness direction can be reduced, and the integration degree is improved. Since the circuit board, the current sensor and the power module are fixedly connected two by two, the integration degree of the three is high, the connection strength is high, and the reliability is high. BRIEF DESCRIPTION OF DRAWINGS

[0016] Figure 1 is a structural schematic view of an embodiment of the power module assembly of the present application;

[0017] Figure 2 is an exploded view of Figure 1 ;

[0018] Figure 3 is a sectional view of an embodiment of the power module assembly of the present application;

[0019] Figure 4is a structural schematic diagram of an embodiment of the current sensor of the present application;

[0020] Figure 5 is a structural schematic diagram of another embodiment of the current sensor of the present application;

[0021] Figure 6 is a sectional view of an embodiment of the current detection unit of the present application. DETAILED DESCRIPTION

[0022] For the purpose of making the object, technical scheme and effect of the present application more clear and explicit, the present application is further described in detail below with reference to the accompanying drawings and embodiments. Obviously, the described embodiments are only some of the embodiments of the present application, but not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0023] Referring to Figure 1 , Figure 1 is a structural schematic diagram of an embodiment of the power module assembly of the present application, Figure 2 is Figure 1 an exploded view of the power module assembly 10. The power module assembly 10 comprises a circuit board 11, a current sensor 12 and a power module 13. The circuit board 11 comprises a driving unit 111 and a control unit 112 arranged side by side, and the driving unit 111 is connected to the control unit 112 through a plurality of through holes 113. The current sensor 12 is arranged on the driving unit 111, and the power module 13 is arranged on the control unit 112. Figure 1As can be seen, the left side of the circuit board 11 is the driving part 111, and a plurality of electronic components (not indicated) are arranged on the driving part 111 for detecting and controlling the power module 13. The right side of the circuit board 11 is the control part 112, and electronic components such as control chips (not indicated) are arranged on the control part 112 for receiving instructions of the whole vehicle and controlling the driving part 111. The power module 13 is connected to one side of the circuit board 11, and the power module 13 is arranged corresponding to the driving part 111, that is, the power module 13 is arranged below the driving part 111. Specifically, the side of the power module 13 facing the circuit board 11 is provided with power module pins 133, which are welded or crimped on the driving part 111 of the circuit board 11. The side of the power module 13 facing the circuit board 11 is also provided with a power module support column 134, the end of which abuts against the side of the circuit board 11 facing the power module 13, thereby ensuring support for the circuit board 11. The power module support column 134 is provided with a mounting hole (not indicated) therein, and a third fixing bolt 153 is threadedly connected in the mounting hole, and the third fixing bolt 153 passes through the circuit board 11 to lock the circuit board 11 in the mounting hole. The current sensor 12 is connected to the side of the circuit board 11 provided with the power module 13, and the current sensor 12 is arranged corresponding to the control part 112, that is, the current sensor 12 is arranged below the control part 112. The current sensor 12 is fixedly connected with the power module 13, and the power module 13 and the current sensor 12 are fixedly arranged below the circuit board 11 in parallel. The power module 13 and the current sensor 12 are respectively fixed with the circuit board 11, that is, the three are fixed as a whole. Optionally, the power module 13 assembly further comprises a housing 14 arranged on the side of the power module 13 and the current sensor 12 away from the circuit board 11. The housing 14 is fixedly connected with the power module 13 and the current sensor 12. Specifically, the housing 14 can be fixedly connected with the power module 13 and the current sensor 12 by fixing bolts (not shown in the figure), thereby ensuring the shock resistance of the components.

[0024] The power module 13 assembly of the present application integrates the circuit board 11, the current sensor 12 and the power module 13 as a whole. The circuit board 11 is arranged on the uppermost layer, and the current sensor 12 and the power module 13 are arranged below the circuit board 11 in parallel and correspond to the respective parts of the circuit board 11. The arrangement space is fully utilized, the power module 13 assembly can reduce the occupied space in the thickness direction, and the integration degree is improved. Since the circuit board 11, the current sensor 12 and the power module 13 are fixedly connected two by two, the integration degree of the three is high, the connection strength is high, and the reliability is high.

[0025] Optionally, continuing to refer to Figure 2 and combining Figure 3 , Figure 3is a sectional view of an embodiment of the power module assembly of the present application. The power module 13 close to one end of the current sensor 12 includes a three-phase output end 131, and the power module 13 away from the current sensor 12 includes a DC connection end 132, the DC connection end 132 is used for high-voltage DC input, the three-phase output end 131 has three terminals arranged side by side, used for outputting three-phase alternating current, and a heat dissipation part 135 is arranged between the three-phase output end 131 and the DC connection end 132, the heat dissipation part 135 is attached to the shell 14, and is used for dissipating heat of the power module 13. The current sensor 12 close to one end of the power module 13 includes a three-phase connection end 121, the three-phase connection end 121 also includes three connection terminals, the three connection terminals of the three-phase output end 131 are fixedly connected with the three terminals of the three-phase connection end 121 respectively, and the power module 13 conducts three-phase alternating current to the motor (not shown in the figure) through the current sensor 12, so as to realize the operation of the motor. The power module 13 of the present application only has one current sensor 12 between the power module 13 and the motor, greatly reduces the number of parts, simplifies the assembly, improves the production efficiency, reduces the switching of the copper bar, greatly reduces the loss caused by the connection of multiple copper bars, and improves the efficiency of the controller.

[0026] Optionally, referring back to Figure 2 and Figure 3 , the power module assembly 10 further includes a first fixing bolt 151, the three-phase output end 131 is provided with a threaded hole 1311, the three-phase connection end 121 is provided with a through hole 1211, and the first fixing bolt 151 passes through the through hole 1211 and is threadedly connected with the threaded hole 1311. Specifically, the first fixing bolt 151 is provided with three, respectively fixing the three terminals of the three-phase output end 131. The power module 13 and the current sensor 12 are stably connected.

[0027] Optionally, the three-phase connection end 121 extends to the side of the three-phase output end 131 facing the circuit board 11, the nut of the first fixing bolt 151 is arranged on the side of the three-phase connection end 121 away from the three-phase output end 131, the circuit board 11 is provided with three avoiding holes 113, the three avoiding holes 113 are arranged along the junction line of the driving part 111 and the control part 112 in sequence, the three connection terminals of the three-phase connection end 121 are respectively located in the three avoiding holes 113, and the nut of the first fixing bolt 151 protruding from the three-phase connection end 121 is also located in the avoiding hole 113 and protrudes from the avoiding hole 113. The present application sets the avoiding hole 113 on the circuit board 11 for accommodating the three-phase connection end 121 and the first fixing bolt 151, so as to avoid the interference between the three-phase connection end 121 and the first fixing bolt 151 and the circuit board 11, and at the same time, the thickness of the power module assembly 10 can be further reduced, and the integration degree is further improved.

[0028] Optionally, referring back to Figure 3The control part 112 is provided with a shielding layer 1121 on the side facing the current sensor 12. Specifically, the shielding layer 1121 is a copper foil attached to the side of the control part 112 facing the current sensor 12. The large-area copper foil is used to reduce the high-frequency radiation interference from the current sensor 12 below the circuit board 11.

[0029] Preferably, referring to Figure 4 and Figure 5 , Figure 4 is a structural schematic diagram of an embodiment of the current sensor of the present application, Figure 5 is a structural schematic diagram of another angle of the current sensor of the present application. The current sensor 12 further comprises a current detection part 122 and a support sealing part 123. The current detection part 122 is connected between the three-phase connection end 121 and the support sealing part 123. The support sealing part 123 is provided with a motor connection end 124 at the end away from the current detection part 122. The motor connection end 124 extends to the side away from the circuit board 11 and penetrates the housing 14. Specifically, the current sensor 12 comprises, in sequence along the direction away from the power module 13, the three-phase connection end 121, the current detection part 122, the support sealing part 123, and the motor connection end 124. The three-phase connection end 121 is used to connect with the power module 13. The motor connection end 124 is used to connect with the motor. The current detection part 122 is used for current detection. The support sealing part 123 is specifically provided with a first sealing groove 1231 and a second sealing groove 1232. The first sealing groove 1231 surrounds the three motor connection ends 124. The first sealing groove 1231 is provided with a sealing ring 1233. The second sealing groove 1232 is provided with three. The three second sealing grooves 1232 are respectively arranged outside the connection terminals of the three motor connection ends 124. The second sealing groove 1232 is provided with potting glue, achieving double sealing.

[0030] Referring to Figure 6 and in combination with Figure 4 , Figure 6is a sectional view of an embodiment of the current detection part of the application. The side of the current detection part 122 facing the circuit board 11 is provided with a sensor pin 1221, which is welded or crimped to the circuit board 11, and is used to transmit the internal current detection signal to the circuit board 11. The two sides of the sensor pin 1221 are respectively provided with positioning columns 1222, which are used to be inserted into the circuit board 11 for positioning. The current sensor 12 and the circuit board 11 are connected in communication through pin welding or crimping, wireless harness transmission, greatly improving the communication connection reliability, simplifying the assembly process, and improving the module integration. Specifically, the current detection part 122 is provided with an integrated circuit board 1223, a Hall magnetic core 1224 and a Hall chip 1225. The Hall chip 1225 is arranged at the opening of the Hall magnetic core 1224, and the sensor pin 1221 and the Hall chip 1225 are connected with the integrated circuit board 1223. The Hall chip 1225 realizes current detection by detecting the magnetic field in the Hall magnetic core 1224. The side of the current detection part 122 close to the three-phase connection end 121 is provided with a magnetic core opening 1226 for assembling the Hall magnetic core 1224, and the inside is filled with glue to ensure the shock resistance of the Hall magnetic core 1224. The side of the current detection part 122 close to the support sealing part 123 is provided with a plug 1227 to prevent glue overflow.

[0031] Optionally, referring to Figure 3 and Figure 4 , the side of the current detection part 122 facing the circuit board 11 is also provided with a sensor support column 1228, which is provided with a mounting hole (not labeled). The power module assembly 10 further includes a second fixing bolt 152, which passes through the circuit board 11 and is threadedly connected with the mounting hole. The sensor support column 1228 abuts against the side of the circuit board 11 facing the current sensor 12, so as to support and fix the circuit board 11.

[0032] To solve the above technical problems, another technical solution adopted by the application is to provide a controller including the power module assembly 10 of any embodiment. The application greatly reduces the number of internal components of the electric control through high integration, avoids wire harness connection, improves the reliability of electrical connection, reduces the manufacturing cost of assembly, and improves the power density of the whole machine.

[0033] The above is only an embodiment of the application, and does not limit the patent scope of the application. Any equivalent structure or equivalent process transformation using the content of the specification and drawings, or direct or indirect application in other related technical fields, is also included in the patent protection scope of the application.

Claims

1. A power module assembly, characterized by The power module assembly comprises: a circuit board, the circuit board comprising a driving part and a control part arranged side by side; a power module connected on one side of the circuit board, the power module corresponding to the driving part; a current sensor connected on the side of the circuit board provided with the power module, the current sensor corresponding to the control part, and the current sensor being fixedly connected with the power module.

2. The power module assembly according to claim 1, wherein the end of the power module close to the current sensor comprises a three-phase output end, and the end of the current sensor close to the power module comprises a three-phase connecting end, the three-phase output end being fixedly connected with the three-phase connecting end.

3. The power module assembly according to claim 2, wherein the power module assembly further comprises a first fixing bolt, the three-phase output end is provided with a threaded hole, the three-phase connecting end is provided with a through hole, and the first fixing bolt passes through the through hole and is threadedly connected with the threaded hole.

4. The power module assembly according to claim 3, wherein the three-phase connecting end is arranged on the side of the three-phase output end facing the circuit board, the circuit board is provided with a relief hole, and the three-phase connecting end is located in the relief hole.

5. The power module assembly according to any one of claims 1-4, wherein the side of the control part facing the current sensor is provided with a shielding layer.

6. The power module assembly according to any one of claims 2-4, wherein the current sensor further comprises a current detection part and a support sealing part, the current detection part is connected between the three-phase connecting end and the support sealing part, the end of the support sealing part away from the current detection part is provided with a motor connecting end, the motor connecting end extends to the side away from the circuit board, the support sealing part is provided with a sealing groove around the motor connecting end, and the sealing groove is provided with a sealing ring.

7. The power module assembly according to claim 6, wherein the side of the current detection part facing the circuit board is provided with a sensor pin, and the sensor pin is welded or crimped with the circuit board.

8. The power module assembly according to claim 6, wherein the side of the current detection part facing the circuit board is further provided with a sensor support column, the sensor support column is provided with a mounting hole, the power module assembly further comprises a second fixing bolt, the second fixing bolt passes through the circuit board and is threadedly connected with the mounting hole, and the sensor support column abuts against the side of the circuit board facing the current sensor.

9. The power module assembly according to any one of claims 1-4, wherein the power module assembly further comprises a shell, the shell is arranged on the side of the power module and the current sensor away from the circuit board, and the shell is fixedly connected with the power module and the current sensor.

10. A controller characterized by comprising: The power module assembly comprises the power module assembly according to any one of claims 1-9.

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