Integrated motor controller and automobile
By using an integrated motor controller to offload the DC bus current at the input of the motor controller and integrating it into the housing, the problems of large DC bus current load and large size at the input of the motor controller are solved, thereby improving safety and integration.
Patent Information
- Application Number
- CN202520637223.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-07
- Publication Date
- 2026-02-03
- Estimated Expiration
- 2035-04-07
AI Technical Summary
In the existing technology, the DC bus current load at the input end of the motor controller of new energy vehicles with distributed drive is large, which poses a safety hazard. In addition, the motor controller is large in size and occupies a large amount of space inside the vehicle.
An integrated motor controller is adopted, including first and second motor controllers, which are connected to the first and second DC buses through first and second DC input ports respectively. A DC support capacitor is used for current shunting, and the motor controller is integrated into the housing to reduce the DC bus current load and controller size.
By reducing the current load on each DC bus through current sharing, the safety hazards during the operation of the motor controller are reduced, the integration of the controller is improved, and the space occupied in the vehicle is reduced.
Smart Images
Figure CN223864699U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of automotive equipment technology, and more specifically, to an integrated motor controller and an automobile. Background Technology
[0002] Currently, the power of drive motors in new energy vehicles is gradually increasing, leading to a growing number of new energy vehicles using distributed drive systems. In existing technologies, multiple motors in a distributed drive system are controlled by a motor controller, resulting in a large current carrying capacity on the DC bus at the input of the motor controller, which poses a safety hazard during the operation of the motor controller.
[0003] In summary, how to reduce the current load on the DC bus at the input of the motor controller is a problem that urgently needs to be solved by those skilled in the art. Utility Model Content
[0004] In view of this, the purpose of this application is to provide an integrated motor controller and automobile that reduces the current load on the DC bus at the input of the motor controller.
[0005] To achieve the above objectives, this application provides the following technical solution:
[0006] An integrated motor controller includes at least a first motor controller and a second motor controller, which are integrated inside a housing. The housing has at least a first DC input port and a second DC input port. The first DC input port is used to connect to a first DC bus and is electrically connected to the first motor controller. The second DC input port is used to connect to a second DC bus and is electrically connected to the second motor controller.
[0007] In some embodiments, the first DC input port is connected to the DC support capacitor via a first connecting copper busbar; the second DC input port is connected to the DC support capacitor via a second connecting copper busbar.
[0008] In some embodiments, the DC support capacitor is a single capacitor, the first DC input port and the second DC input port are connected to the same DC support capacitor, and the DC support capacitor is integrated inside the housing.
[0009] In some embodiments, the DC support capacitor includes a capacitor housing and a capacitor body, wherein the capacitor housing and the capacitor body are integrally encapsulated, and the capacitor housing is made of metal.
[0010] In some embodiments, the DC support capacitor is connected to the drive module via a third connecting copper busbar; the drive module is electrically connected to both the first motor controller and the second motor controller.
[0011] In some embodiments, the housing is further provided with a first three-phase output port and a second three-phase output port; the first three-phase output port is used to connect to a first output wire, and the first motor controller is connected to a first drive motor through the first output wire; the second three-phase output port is used to connect to a second output wire, and the second motor controller is connected to a second drive motor through the second output wire.
[0012] In some embodiments, the first DC input port and the second DC input port are located on opposite sides of the housing; or, the first DC input port and the second DC input port are located on the same side of the housing.
[0013] In some embodiments, the first DC bus is used to connect the first DC input port and the power battery pack; the second DC bus is used to connect the second DC input port and the power battery pack.
[0014] In some embodiments, the housing is further provided with a low-voltage plug-in port for connecting a low-voltage control line;
[0015] And / or, the integrated motor controller further includes a resolver cylinder insert, which is integrated inside the housing.
[0016] An automobile includes an integrated motor controller as described above.
[0017] The integrated motor controller provided in this application includes at least a first motor controller and a second motor controller integrated inside a housing. The housing has at least a first DC input port electrically connected to the first motor controller and a second DC input port electrically connected to the second motor controller. The first DC input port is used to connect to a first DC bus, and the second DC input port is used to connect to a second DC bus. The current carried by the DC bus at the input end of the motor controller is distributed through at least two DC buses, which reduces the current load of each DC bus and reduces the safety hazards during the operation of the motor controller. Attached Figure Description
[0018] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of this application. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.
[0019] Figure 1 This is a schematic diagram of the current flow in a motor controller in the prior art;
[0020] Figure 2 This is a top view of the motor controller provided in an embodiment of this application;
[0021] Figure 3 This is a side view of the motor controller provided in an embodiment of this application;
[0022] Figure 4 This is a schematic diagram of the internal structure of the motor controller provided in an embodiment of this application;
[0023] Figure 5 This is a schematic diagram of the current flow of the motor controller provided in an embodiment of this application.
[0024] Explanation of reference numerals in the attached figures:
[0025] 1-First DC input port, 2-Second DC input port, 3-DC support capacitor, 4-First connecting copper busbar, 5-Second connecting copper busbar, 6-Third connecting copper busbar, 7-First motor controller, 8-Second motor controller, 9-Drive module, 10-First three-phase output port, 11-Second three-phase output port, 12-Low voltage plug-in port, 13-Resolver cylinder component, 14-Housing. Detailed Implementation
[0026] 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, and 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.
[0027] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. The terminology used in the following embodiments is for the purpose of describing specific embodiments only and is not intended to be a limitation of this application. As used in the specification and appended claims of this application, the singular expressions "a," "an," "the," "the," "the," and "this" are intended to also include expressions such as "one or more," unless the context clearly indicates otherwise. It should also be understood that in the embodiments of this application, "one or more" refers to one, two, or more; "and / or" describes the relationship between related objects, indicating that three relationships may exist; for example, A and / or B can represent: A alone, A and B simultaneously, or B alone, where A and B can be singular or plural. The character " / " generally indicates that the preceding and following related objects are in an "or" relationship.
[0028] References to "one embodiment" or "some embodiments" as described in this specification mean that one or more embodiments of this application include a specific feature, structure, or characteristic described in connection with that embodiment. Therefore, the phrases "in one embodiment," "in some embodiments," "in other embodiments," "in still other embodiments," etc., appearing in different parts of this specification do not necessarily refer to the same embodiment, but rather mean "one or more, but not all, embodiments," unless otherwise specifically emphasized. The terms "comprising," "including," "having," and variations thereof mean "including but not limited to," unless otherwise specifically emphasized.
[0029] The "multiple" mentioned in the embodiments of this application refers to two or more. It should be noted that in the description of the embodiments of this application, terms such as "first" and "second" are used only for the purpose of distinguishing descriptions and should not be construed as indicating or implying relative importance, nor should they be construed as indicating or implying order.
[0030] like Figure 1 As shown, existing dual-motor controllers typically only physically integrate two motor controllers, resulting in a single DC input interface. This forces the DC bus to carry the current flowing through both motor controllers. Under high-power / high-current input conditions, the current load on the DC bus becomes substantial, posing a safety hazard during operation. Furthermore, each motor controller in existing dual-motor controllers corresponds to a DC support capacitor, resulting in a large overall size and requiring significant interior space.
[0031] To address the aforementioned technical problems, this application provides an integrated motor controller to reduce the current load on the DC bus at the input terminal of the motor controller.
[0032] like Figures 2-4 As shown, the integrated motor controller provided in this application embodiment includes at least a first motor controller 7 and a second motor controller 8, and the first motor controller 7 and the second motor controller 8 are integrated inside the housing 14; the housing 14 has at least a first DC input port 1 and a second DC input port 2, the first DC input port 1 is electrically connected to the first motor controller 7, and the first DC input port 1 is used to connect to the first DC bus; the second DC input port 2 is electrically connected to the second motor controller 8, and the second DC input port 2 is used to connect to the second DC bus; in this way, during the operation of the integrated motor controller, the corresponding current can be carried through at least the first DC bus and the second DC bus respectively, and the current carried by the DC bus at the input end of the motor controller can be distributed through at least two DC buses, reducing the current load of each DC bus and reducing the safety hazards during the operation of the motor controller.
[0033] It should be noted that the first end of the first DC bus is connected to the first DC input port 1, and the second end of the first DC bus is connected to the power battery pack to transmit the current provided by the power battery pack; the first end of the second DC bus is connected to the second DC input port 2, and the second end of the second DC bus is connected to the power battery pack to transmit the current provided by the power battery pack. In this way, during actual operation, the first DC bus and the second DC bus respectively carry the corresponding current from the power battery pack, reducing the current load of each DC bus.
[0034] In some embodiments, when the current load is larger, a third DC input port, a fourth DC input port, etc., can be added to increase the connection between the third DC bus, the fourth DC bus and the corresponding DC input port, so as to further distribute the current by increasing the number of DC buses and reduce the current load of each DC bus. The specific number of DC input ports and the corresponding number of DC buses can be selected according to the actual situation, and this application embodiment does not limit this.
[0035] In some embodiments, such as Figures 2-3 As shown, the first DC input port 1 and the second DC input port 2 are located on opposite sides of the housing 14 to facilitate the wiring of the first DC bus and the second DC bus and improve convenience.
[0036] In some other embodiments, the first DC input port 1 and the second DC input port 2 may also be located on the same side of the housing 14. The relative positions of the first DC input port 1 and the second DC input port 2 can be set according to the actual arrangement. This application embodiment does not limit this.
[0037] like Figure 4As shown, the first DC input port 1 is connected to the DC support capacitor 3 through the first connecting copper busbar 4, and the second DC input port 2 is connected to the DC support capacitor 3 through the second connecting copper busbar 5, so that the DC support capacitor 3 can realize the functions of energy storage, filtering and voltage stabilization during the operation of the integrated motor controller.
[0038] It should be noted that the DC support capacitor 3 is a common and important component in motor controllers. It plays a core role in energy storage, filtering and voltage stabilization within the motor controller, which will not be elaborated here.
[0039] like Figure 4 As shown, the integrated motor controller provided in this application embodiment includes only one DC support capacitor 3. The first DC input port 1 and the second DC input port 2 are connected to the same DC support capacitor 3, and the DC support capacitor 3 is integrated inside the housing 14. The voltage of the first motor controller 7 and the second motor controller 8 is carried by one DC support capacitor 3, which reduces the size of the motor controller, improves the integration of the motor controller, and reduces the space occupied by the motor controller in the vehicle.
[0040] It should be noted that, in practice, a larger capacity DC support capacitor carries the voltage of the first motor controller 7 and the second motor controller 8. For example, if the original DC support capacitor corresponding to each motor controller is 400uF, the capacity of the DC support capacitor can be increased to 800uF to achieve synchronous carrying of the first motor controller 7 and the second motor controller 8. Since the integration of a large capacity DC support capacitor is higher than that of two small capacity DC support capacitors physically stacked, the integration of the motor controller is improved by using a single DC support capacitor 3, and the space occupied by the motor controller in the vehicle is reduced.
[0041] To further improve the integration of the motor controller, the DC support capacitor 3 includes a capacitor shell and a capacitor body. The capacitor shell and the capacitor body are integrally encapsulated, and the capacitor shell is made of metal. By integrally encapsulating the capacitor shell and the capacitor body, the integration of the DC support capacitor 3 is further improved, thereby improving the integration of the motor controller.
[0042] like Figure 4As shown, the DC support capacitor 3 is connected to the drive module 9 via the third connecting copper busbar 6. The drive module 9 is electrically connected to both the first motor controller 7 and the second motor controller 8. The housing 14 also has a first three-phase output port 10 and a second three-phase output port 11. The first three-phase output port 10 is connected to a first output wire, and the first motor controller 7 is connected to the first drive motor via the first output wire to achieve drive control of the first drive motor. The second three-phase output port 11 is connected to a second output wire, and the second motor controller 8 is connected to the second drive motor via the second output wire to achieve drive control of the second drive motor, so as to control the distributed drive motor through the integrated motor controller.
[0043] In practice, such as Figures 3-4 As shown, the housing 14 has a low-voltage plug-in port 12 for connecting the low-voltage control line, so as to realize the transmission of control signals, sensor data and communication information by the motor controller.
[0044] The integrated motor controller also includes a resolver cylinder 13, and there are two resolver cylinder 13s. The two resolver cylinder 13s are integrated inside the housing 14 to ensure the stability and reliability of the resolver operation.
[0045] When the integrated motor controller provided in the embodiments of this application is in operation, such as Figure 5 As shown, the first DC bus and the second DC bus transmit the current of the power battery pack to the first motor controller 7 and the second motor controller 8 through the first DC input port 1 and the second DC input port 2, respectively, which reduces the current load of each DC bus and reduces the safety hazards during the operation of the motor controller; and the first motor controller 7 and the second motor controller 8 carry voltage through the same DC support capacitor 3, which improves the integration of the motor controller.
[0046] This application also provides a vehicle that includes the integrated motor controller described in the above embodiments.
[0047] Since the aforementioned integrated motor controller has the aforementioned technical effects, and the aforementioned automobile includes the aforementioned integrated motor controller, the aforementioned automobile also has the corresponding technical effects, which will not be elaborated here.
[0048] The above description of the disclosed embodiments enables those skilled in the art to make or use this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims
1. An integrated motor controller, characterized in that, It includes at least a first motor controller (7) and a second motor controller (8), which are integrated inside the housing (14); The housing (14) has at least a first DC input port (1) and a second DC input port (2). The first DC input port (1) is used to connect to the first DC bus and is electrically connected to the first motor controller (7). The second DC input port (2) is used to connect to the second DC bus, and the second DC input port (2) is electrically connected to the second motor controller (8).
2. The integrated motor controller according to claim 1, characterized in that, The first DC input port (1) is connected to the DC support capacitor (3) through the first connecting copper busbar (4); The second DC input port (2) is connected to the DC support capacitor (3) via the second connecting copper busbar (5).
3. The integrated motor controller according to claim 2, characterized in that, The DC support capacitor (3) is one, and the first DC input port (1) and the second DC input port (2) are connected to the same DC support capacitor (3), and the DC support capacitor (3) is integrated inside the housing (14).
4. The integrated motor controller according to claim 2, characterized in that, The DC support capacitor (3) includes a capacitor shell and a capacitor body. The capacitor shell and the capacitor body are an integral encapsulated structure, and the capacitor shell is made of metal.
5. The integrated motor controller according to claim 2, characterized in that, The DC support capacitor (3) is connected to the drive module (9) via the third connecting copper busbar (6). The drive module (9) is electrically connected to both the first motor controller (7) and the second motor controller (8).
6. The integrated motor controller according to claim 5, characterized in that, The housing (14) is also provided with a first three-phase output port (10) and a second three-phase output port (11). The first three-phase output port (10) is used to connect the first output wire, and the first motor controller (7) is connected to the first drive motor through the first output wire; The second three-phase output port (11) is used to connect the second output wire, and the second motor controller (8) is connected to the second drive motor through the second output wire.
7. The integrated motor controller according to claim 1, characterized in that, The first DC input port (1) and the second DC input port (2) are located on opposite sides of the housing (14); Alternatively, the first DC input port (1) and the second DC input port (2) are located on the same side of the housing (14).
8. The integrated motor controller according to claim 1, characterized in that, The first DC bus is used to connect the first DC input port (1) and the power battery pack; The second DC bus is used to connect the second DC input port (2) and the power battery pack.
9. The integrated motor controller according to any one of claims 1-8, characterized in that, The housing (14) is also provided with a low-voltage plug-in port (12) for connecting a low-voltage control line. And / or, the integrated motor controller further includes a resolver cylinder insert (13), which is integrated inside the housing (14).
10. A car, characterized in that, Including the integrated motor controller as described in any one of claims 1-9.